Perkins ENGINE 1200E Series Models BK, BL, MK and ML ELECTRICAL & ELECTRONIC A&I

Perkins ENGINE

1200E Series

Models BK, BL, MK and ML

ELECTRICAL & ELECTRONIC A&I

GUIDE

1204E-E44TA

1204E-E44TTA

1206E-E66TA

1206E-E70TTA

Four & Six cylinder diesel engines for

agricultural, industrial, construction

applications

• Pages: 255
• Size: 3.63 MB
• Format: PDF (Adobe Reader)
• Language : English

CONTENTS

1.0 INTRODUCTION AND PURPOSE ............................................................9

1.1 APPLICABLE ENGINES .....................................................................................................................9

1.2 ELECTRONIC APPLICATIONS CONTACTS..........................................................................................9

1.3 SAFETY ...........................................................................................................................................9

1.3.1 Warning – Welding................................................................................................................10

1.3.2 Warning - Electrostatic Paint Spraying.................................................................................10

1.3.3 Warning – Jump Starting.......................................................................................................10

2.0 ENGINE & AFTERTREATMENT COMPONENT OVERVIEW................11

2.1 MAIN ENGINE SENSOR AND ACTUATOR DETAILS .........................................................................11

2.1.1 Electronic Control Module (ECM)........................................................................................12

2.1.2 Fuel System............................................................................................................................12

2.1.3 Engine Speed .........................................................................................................................12

2.1.4 Core Engine System...............................................................................................................13

2.1.5 NRS (Nox Reduction System).................................................................................................13

2.1.6 Air System..............................................................................................................................14

2.1.7 Emissions System Assist Devices ...........................................................................................14

2.2 AFTERTREATMENT SYSTEM SENSOR & ACTUATOR DETAILS........................................................15

2.2.1 ARD (Auxiliary Regeneration Device) System ......................................................................15

2.2.2 DPF System ...........................................................................................................................16

2.3 SYSTEM COMPONENT DIAGRAMS AND SCHEMATICS.....................................................................17

2.3.1 1204E-E44TA Factory Installed Wiring and Components ....................................................17

2.3.2 1204E-E44TA Customer Installed Aftertreatment Wiring & Components............................18

2.3.3 1206E-E66TA Factory Installed Wiring and Components ....................................................19

2.3.4 1206E-E66TA Customer Installed Aftertreatment Wiring & Components............................20

2.3.5 1206E-E70TTA Factory Installed Wiring and Components..................................................21

2.3.6 1206E-E70TTA Customer Installed Aftertreatment Wiring & Components..........................22

2.4 ENGINE & AFTERTREATMENT COMPONENT LAYOUT DIAGRAMS .................................................23

2.4.1 1204E Principle Engine Electronic Components ..................................................................23

2.4.2 1206E Principle Engine Electronic Components ..................................................................24

2.4.3 1206E-E70TTA Principle Engine And Aftertreatment...........................................................25

2.4.4 1206E-E70TTA CEM Principle Electronic Components.......................................................26

3.0 CUSTOMER SYSTEM OVERVIEW KEY ELEMENTS............................27

3.1 AFTERTREATMENT CONNECTIONS ................................................................................................27

3.2 CONNECTION, POWER AND GROUNDING.......................................................................................27

3.3 INDICATION, STARTING AND STOPPING THE ENGINE.....................................................................27

3.4 CONTROLLING THE ENGINE...........................................................................................................28

3.5 AFTERTREATMENT OPERATION AND REGENERATION ...................................................................28

3.8 OPTIONAL CUSTOMER INSTALLED COMPONENTS .........................................................................30

3.9 TYPICAL CUSTOMER INSTALLED COMPONENT DIAGRAM .............................................................31

3.9.1 Example OEM Schematic ......................................................................................................31

3.9.2 Example 1 Basic Engine Application.....................................................................................31

3.9.3 Example 2 Construction Application.....................................................................................31

3.9.4 Example 3 Agricultural Application......................................................................................31

3.9.5 Example 1 - Basic Schematic OEM Harness.........................................................................32

3.9.6 Example 2 - Construction Schematic OEM Harness.............................................................33

3.9.7 Example 3 - Agricultural Schematic OEM Harness ..............................................................34

4.0 POWER AND GROUNDING CONSIDERATIONS..................................35

4.1 ENGINE BLOCK GROUNDING.........................................................................................................35

4.1.1 Ground stud on Starter Motor ...............................................................................................35

4.1.2 Ground Connection to Tapping on engine Block ..................................................................35

4.1.3 CEM Grounding 1206E-E70TTA ..........................................................................................37

4.2 VOLTAGE AND CURRENT REQUIREMENTS .....................................................................................38

4.3 ECM POWER SUPPLY CIRCUIT RESISTANCE ...................................................................................39

4.3.1 Important Voltage Supply Circuit Considerations ................................................................41

Electrical & Electronic Application And Installation Guide 1200E Series

Draft Release Version P1, Publication TPD1725E1 Page 3 of 254

Created On 11/10/2011 13:26

4.3.2 Battery (+) Connection..........................................................................................................41

4.3.3 Battery (-) Connection ...........................................................................................................43

4.3.4 Correct method of ECM battery connection..........................................................................44

4.3.5 Incorrect method of ECM battery connection. ......................................................................44

4.4 ENGINE ECM POWER SUPPLY CIRCUIT RESISTANCE TEST ...........................................................45

4.4.1 Test Procedure.......................................................................................................................46

4.4.2 Suppression of Voltage Transients ........................................................................................46

4.5 DIRECT BATTERY CONNECTION REQUIREMENTS ...........................................................................48

4.6 POWERING THE ENGINE ECM VIA AUXILIARY POWER SUPPLIES.................................................48

4.7 SENSOR COMMON CONNECTIONS..................................................................................................48

4.7.1 Actuator Driver Return..........................................................................................................49

4.7.2 Analogue Sensor Return ........................................................................................................49

4.7.3 Switch Return.........................................................................................................................49

4.7.4 Digital Return........................................................................................................................50

4.8 MANDATORY FUEL LIFT PUMP INSTALLATION .............................................................................50

4.8.1 Fuel Lift Pump Operation......................................................................................................50

4.8.2 Fuel Lift Pump Configuration ...............................................................................................50

4.8.3 Fuel Lift Pump Installation....................................................................................................51

5.0 CONNECTORS AND WIRING HARNESS REQUIREMENTS................53

5.1 ENGINE ECM J1 CONNECTOR .......................................................................................................53

5.1.1 Connector Layout ..................................................................................................................54

5.1.2 Tightening the OEM Connector.............................................................................................54

5.1.3 ECM connector Wire Gauge Size ..........................................................................................54

5.1.4 Terminal Retention ................................................................................................................55

5.1.5 Hand Crimping For Prototype machines and Low Volume Production: ..............................55

5.1.6 ECM connector sealing plug installation guidelines.............................................................55

5.1.7 OEM harness Dress Cover With Integrated Strain Relief .....................................................55

5.1.8 Machine Crimping For High Volume Production .................................................................56

5.2 ENGINE TO AFTERTREATMENT CONNECTORS 1206E-E70TTA ONLY ..........................................57

5.2.1 40 Way CEM Connector Layout 1206E-E70TTA..................................................................57

5.2.2 Engine Harness 31 pin Connector Layout 1206E-E70TTA...................................................58

5.2.3 Tightening the Connectors.....................................................................................................58

5.2.4 Aftertreatment Connectors Wire Gauge Size.........................................................................58

5.2.5 Connector Sealing Plug Installation Guidelines ...................................................................59

5.2.6 OEM Harness Retention........................................................................................................59

5.2.7 Harness Routing and Length Restrictions .............................................................................59

5.3 DIAGNOSTIC CONNECTOR .............................................................................................................60

5.3.1 Diagnostic Connector Layout................................................................................................60

5.3.2 Diagnostic Connector Wire Gauge Size ................................................................................61

5.3.3 Pin Information .....................................................................................................................61

5.4 CONNECTOR TERMINAL CONTACTS ..............................................................................................62

5.5 HARNESS WIRING STANDARDS .....................................................................................................63

5.4.1 Connectors.............................................................................................................................63

5.4.2 Harness Bends Near Connectors...........................................................................................63

5.4.3 Cable routing.........................................................................................................................64

5.4.5 Electromagnetic Compliance (EMC).....................................................................................65

5.4.6 Insulation Selection and Thermal Protection ........................................................................65

6.0 CONNECTING TO ENGINE AFTERTREATMENT .................................66

6.1 1204E AND 1206E EMISSION CRITICAL AFTERTREATMENT INSTALLATION .................................67

6.1.1 Low Temperature Regeneration System Overview ................................................................67

6.1.2 Low Temperature Regeneration ............................................................................................68

6.1.3 System Connection and Harness Design ...............................................................................69

6.1.4 Aftertreatment Wiring Schematic ..........................................................................................70

6.2 1206E-E70TTA EMISSION CRITICAL AFTERTREATMENT .............................................................71

6.2.1 High Temperature Regenerations System Overview .............................................................71

6.2.2 High Temperature ARD Regeneration ..................................................................................72

6.2.3 1206E-E70TTA High Temperature Regeneration System Connection and Harness Design.73

6.2.4 Aftertreatment Wiring Schematic ..........................................................................................77

Electrical & Electronic Application And Installation Guide 1200E Series

Draft Release Version P1, Publication TPD1725E1 Page 4 of 254

Created On 11/10/2011 13:26

6.4 AUXILIARY SENSOR INSTALLATION AND CONNECTION ................................................................78

6.4.1 DPF Soot Sensor ...................................................................................................................78

6.4.2 Air Inlet Temperature Sensor ................................................................................................82

6.4.3 DPF Inlet Temperature Sensor..............................................................................................84

6.4.4 DPF Identification Module....................................................................................................86

6.4.5 ARD Fuel Pump.....................................................................................................................87

7.0 STARTING AND STOPPING THE ENGINE ...........................................92

7.1 STARTING THE ENGINE..................................................................................................................92

7.2 STOPPING THE ENGINE (AND PREVENTING RESTART) ...................................................................93

7.2.1 Ignition Keyswitch .................................................................................................................93

7.2.2 Battery Isolation Switches .....................................................................................................94

7.2.3 User Defined Shutdown Switch (Remote Shutdown) .............................................................94

7.2.4 Intake Air Shutoff Valve.........................................................................................................95

7.2.5 Overspeed Verify Switch........................................................................................................96

7.2.6 Datalink stops........................................................................................................................96

7.2.7 Common problems with the application of stop devices........................................................97

8.0 MACHINE FAN CONTROL .....................................................................98

8.1 HYDRAULIC FAN CONTROL OPERATION .......................................................................................98

8.1.1 Machine Fan Control Operation ...........................................................................................98

8.1.2 Machine Fan Control Configuration.....................................................................................98

8.1.3 Machine Fan Control Installation .........................................................................................99

9.0 ENGINE SPEED DEMAND ...................................................................101

9.1 ANALOGUE SENSOR ....................................................................................................................102

9.1.1 Analogue Sensor Operation.................................................................................................102

9.1.2 Analogue Sensor Configuration ..........................................................................................102

9.1.3 Analogue Sensor Installation...............................................................................................103

9.1.4 Evaluating Component Compatibility (Testing) ..................................................................103

9.2 PWM SENSOR - COMPATIBILITY................................................................................................106

9.2.1 PWM Sensor Operation.......................................................................................................106

9.2.2 PWM Sensor Configuration.................................................................................................107

9.2.3 PWM Sensor Installation.....................................................................................................107

9.3 THROTTLE LOCK (PTO MODE)....................................................................................................108

9.3.1 Throttle Lock Mode Operation ............................................................................................108

9.3.2 Throttle Lock Mode Configuration......................................................................................112

9.3.2 Throttle Lock Mode Installation ..........................................................................................112

9.3.3 Throttle Lock Operation Under Engine Load......................................................................113

9.4 MULTI POSITION THROTTLE SWITCH (MPTS).............................................................................114

9.4.1 MPTS Operation..................................................................................................................114

9.4.2 MPTS Configuration............................................................................................................115

9.4.3 MPTS Installation................................................................................................................115

9.5 TORQUE SPEED CONTROL TSC1 (SPEED CONTROL OVER CAN)................................................116

9.6 ARBITRATION OF SPEED DEMAND................................................................................................116

9.6.1 Manual Throttle Selection Switch........................................................................................116

9.7 ACCELERATION AND DECELERATION RAMP RATES ....................................................................116

9.8 THROTTLE BEHAVIOR DURING ENGINE GOVERNOR CHANGES ...................................................117

9.9.1 Throttle Parameter Description ..........................................................................................120

9.9.2 Throttle Calibration Function .............................................................................................122

9.9.3 Idle Validation Switch .........................................................................................................126

9.10 DEFINITION OF ENGINE SPEED POINTS ......................................................................................127

9.10.1 Engine Low Idle.................................................................................................................128

9.10.2 Engine High Idle................................................................................................................128

9.10.3 Engine Rated Speed...........................................................................................................129

10.0 COLD WEATHER ENGINE OPERATION & STARTING AIDS ..........130

10.1 CONTROL OF GLOW PLUGS BY THE ENGINE ECM.....................................................................132

10.1.1 Glow Plug System Operation.............................................................................................132&l