Perkins ENGINE
1200F Series
Models MT, MU, MV, MW, BM and BN
ELECTRONIC APPLICATION &
INSTALLATION MANUAL
1204F-E44TA Four & six cylinder diesel
1204F-E44TTA engines for agricultural,
1206F-E70TA industrial, construction
1206F-E70TTA applications
Developed
- Pages: 257
- Size: 6.19 MB
- Format: PDF (Adobe Reader)
- Language : English
CONTENTS
1.0 SAFETY .................................................................................................... 9
1.1 WARNING – WELDING ..................................................................................................................... 9
1.1.2 Warning - Electrostatic Paint Spraying .................................................................................. 9
1.1.3 Warning – Jump Starting ...................................................................................................... 10
2.0 ENGINE & AFTERTREATMENT COMPONENT OVERVIEW ................ 11
2.1 MAIN ENGINE SENSOR AND ACTUATOR DETAIL ........................................................................... 11
2.1.1 Electronic Control Module .................................................................................................... 11
2.1.2 Fuel System ........................................................................................................................... 11
2.1.3 Engine Speed ......................................................................................................................... 12
2.1.4 NRS (NOx Reduction System) ................................................................................................ 12
2.1.5 Core Engine System ............................................................................................................... 12
2.1.6 Air System .............................................................................................................................. 13
2.1.7 Emissions System Assist Devices ........................................................................................... 13
2.2 AFTERTREATMENT SYSTEM SENSOR & ACTUATOR DETAILS ........................................................ 13
2.2.1 PM Capture Devices ............................................................................................................. 13
2.2.3 Selective Catalytic Reduction (SCR) Technologies ............................................................... 14
2.3 SYSTEM COMPONENT DIAGRAMS & SCHEMATICS ........................................................................ 15
2.3.1 1204F Engine and Aftertreatment Layout ............................................................................. 15
2.3.2 1206F Engine and Aftertreatment Layout ............................................................................. 18
2.4 ENGINE & AFTERTREATMENT COMPONENT LAYOUT DIAGRAMS ................................................. 20
2.4.1 1204F Principal Engine Electronic Components .................................................................. 20
2.4.2 1206F Principal Engine Electronic Components .................................................................. 23
2.4.3 1204F AT Principal Components .......................................................................................... 26
2.4.4 1206F AT Principal Components .......................................................................................... 27
3.0 CUSTOMER SYSTEM OVERVIEW KEY ELEMENTS ........................... 28
3.1 AFTERTREATMENT CONFIGURATIONS ........................................................................................... 28
3.2 TIER 4F MANDATORY INSTALL COMPONENTS .............................................................................. 28
3.3 OPTIONAL CUSTOMER INSTALLED COMPONENTS ......................................................................... 29
4.0 POWER & GROUNDING CONSIDERATIONS ....................................... 30
4.1 SYSTEM GROUNDING .................................................................................................................... 30
4.1.1 Ground Stud On Starter Motor .............................................................................................. 30
4.1.2 Engine Block Ground Connection ......................................................................................... 30
4.1.3 Aftertreatment System Grounding ......................................................................................... 31
4.2 SYSTEM VOLTAGE & CURRENT REQUIREMENTS ........................................................................... 32
4.2.1 Engine ECM .......................................................................................................................... 32
4.2.2 1204F DEF System ................................................................................................................ 32
4.2.3 1206F DEF System ................................................................................................................ 33
4.2.4 System Effect on Alternator Specification ............................................................................. 33
4.3 ECM POWER SUPPLY & CIRCUIT RESISTANCE ............................................................................. 34
4.3.1 Important Voltage Supply Circuit Considerations ................................................................ 36
4.3.2 Battery (+) Connection ......................................................................................................... 36
4.3.3 Battery (-) Connection ........................................................................................................... 38
4.3.4 Correct method of ECM battery connection. ......................................................................... 39
4.3.5 Incorrect method of ECM battery connection. ...................................................................... 39
4.4 ENGINE ECM POWER SUPPLY CIRCUIT RESISTANCE TEST ........................................................... 40
4.4.1 Test Procedure ...................................................................................................................... 40
4.5 DEF SYSTEM POWER SUPPLY ....................................................................................................... 42
4.5.1 1204F DEF System Power Supply connection ...................................................................... 42
4.5.2 1206F DEF System Power Supply Connection ..................................................................... 43
4.6 SUPPRESSION OF VOLTAGE TRANSIENTS ....................................................................................... 44
4.6.1 Suppression Methods & Best Practice .................................................................................. 44
4.7 DIRECT BATTERY CONNECTION REQUIREMENTS ........................................................................... 45
4.8 POWERING THE ENGINE ECM VIA AUXILIARY POWER SUPPLIES ................................................. 46
4.9 SENSOR COMMON CONNECTIONS .................................................................................................. 46
Electrical & Electronic Application And Installation Manual
Production Release Version 1.0
Page 3
4.9.1 Actuator Driver Return ......................................................................................................... 46
4.9.2 Analogue Sensor Return ........................................................................................................ 46
4.9.3 Switch Return ........................................................................................................................ 47
4.9.4 Digital Return ........................................................................................................................ 47
5.0 CONNECTORS & WIRING HARNESS REQUIREMENTS ..................... 48
5.1 ENGINE ECM J1 CONNECTOR ....................................................................................................... 48
5.1.1 J1 Connector Layout ............................................................................................................. 48
5.1.2 Tightening The OEM Connector ........................................................................................... 49
5.1.3 ECM Connector Wire Gauge Sealing Capability .................................................................. 49
5.1.4 Hand Crimping For Prototype machines and Low Volume Production: .............................. 49
5.1.5 ECM connector sealing plug installation guidelines ............................................................. 49
5.1.6 OEM harness Dress Cover With Integrated Strain Relief ..................................................... 49
5.1.7 Machine Crimping For High Volume Production ................................................................. 50
5.2 ENGINE ECM J1 CONNECTOR I/O ................................................................................................. 50
5.3 ECM CONNECTOR ASSEMBLY & DISASSEMBLY ........................................................................... 53
5.3.1 Connector Assembly .............................................................................................................. 53
5.3.2 Connector Disassembly ......................................................................................................... 55
5.4 DIAGNOSTIC CONNECTOR ............................................................................................................. 56
5.4.1 Diagnostic Connector Layout ................................................................................................ 56
5.4.2 Diagnostic Connector Wire Gauge Size ................................................................................ 56
5.4.3 Pin Information ..................................................................................................................... 57
5.5 MANDATORY ENGINE & AFTERTREATMENT CONNECTORS .......................................................... 58
5.6 CONNECTOR TERMINAL CONTACTS .............................................................................................. 58
5.7 WIRE SPECIFICATION REQUIREMENTS .......................................................................................... 58
5.7.1 Wire Thickness Overview ...................................................................................................... 59
5.8 HARNESS WIRING STANDARDS ..................................................................................................... 60
5.8.1 Connectors ............................................................................................................................ 60
5.8.2 Harness Bends Near Connectors ........................................................................................... 61
5.8.3 Cable routing ......................................................................................................................... 61
5.8.4 Electromagnetic Compatibility (EMC) .................................................................................. 62
5.8.5 Insulation Selection and Thermal Protection ........................................................................ 62
6.0 CUSTOMER CONNECTION OF ENGINE COMPONENTS .................... 63
6.1 WATER IN FUEL SWITCH ............................................................................................................... 63
6.1.1 WIF Switch Operation ........................................................................................................... 63
6.1.2 WIF Switch Configuration ..................................................................................................... 63
6.1.3 WIF Switch Installation ......................................................................................................... 64
6.2 AMBIENT AIR TEMPERATURE SENSOR .......................................................................................... 64
6.2.1 Ambient Air Temperature Sensor Operation ......................................................................... 64
6.2.2 Ambient Air Temperature Sensor Configuration ................................................................... 65
6.2.3 Ambient Air Temperature Sensor Installation ....................................................................... 65
6.3 ENGINE ELECTRICAL FUEL LIFT PUMP .......................................................................................... 66
6.3.1 Engine Electrical Fuel Lift Pump Operation......................................................................... 66
6.3.2 Engine Electrical Fuel Lift Pump Configuration .................................................................. 66
6.3.3 Engine Electrical Fuel Lift Pump Installation....................................................................... 66
7.0 1204F CONNECTING TO THE ENGINE AFTERTREATMENT.............. 70
7.1 DOC + DPF + SCR ....................................................................................................................... 70
7.1.1 System Architecture ............................................................................................................... 70
7.1.2 Electrical Connections .......................................................................................................... 71
7.1.3 Component I/O ...................................................................................................................... 72
7.2 DOC + SCR .................................................................................................................................. 74
7.2.1 System Architecture ............................................................................................................... 74
7.2.2 Electrical Connections .......................................................................................................... 74
7.2.3 Component I/O ...................................................................................................................... 76
7.3 1204F DEF SYSTEM ...................................................................................................................... 77
7.3.1 System Architecture ............................................................................................................... 77
7.3.2 PEU Electrical Connections & Component Installation Requirements ................................ 78
Electrical & Electronic Application And Installation Manual
Production Release Version 1.0
Page 4
7.3.3 Component I/O ...................................................................................................................... 84
7.4 1204F AFTERTREATMENT WIRING SCHEMATICS ........................................................................... 86
7.4.1 1204F DOC & SCR Schematic .............................................................................................. 86
7.4.2 1204F DOC, DPF & SCR Schematic .................................................................................... 87
8.0 1206F CONNECTING TO THE ENGINE AFTERTREATMENT.............. 88
8.1 IG CEM ........................................................................................................................................ 88
8.1.1 System Architecture ............................................................................................................... 88
8.1.2 IG CEM Electrical Connections ............................................................................................ 90
8.1.3 Component I/O ...................................................................................................................... 91
8.2 1206F PUMP ELECTRONICS & TANK UNIT (PETU) ....................................................................... 93
8.2.1 PETU System Architecture .................................................................................................... 93
8.2.2 PETU Electrical Connections & Component Installation Requirements .............................. 94
8.2.3 Component I/O .................................................................................................................... 100
8.3 1206F AFTERTREATMENT WIRING SCHEMATIC .......................................................................... 101
9.0 COMPONENT INSTALLATION REQUIREMENTS .............................. 102
9.1 DPF SOOT SENSOR ...................................................................................................................... 102
9.1.1 DPF Soot Sensor Operation ................................................................................................ 102
9.1.2 DPF Soot Sensor Configuration .......................................................................................... 102
9.1.3 DPF Soot Sensor Installation .............................................................................................. 102
9.2 NOX SENSOR .............................................................................................................................. 106
9.2.1 NOx Sensor Operation ........................................................................................................ 106
9.2.2 NOx Sensor Configuration .................................................................................................. 107
9.2.3 NOx Sensor Installation ...................................................................................................... 107
9.3 AMMONIA (NH3)SENSOR ............................................................................................................ 110
9.3.1 Ammonia (NH3) Sensor Operation ..................................................................................... 110
9.3.2 Ammonia (NH3) Sensor Configuration ............................................................................... 111
9.3.3 Ammonia (NH3) Sensor Installation ................................................................................... 111
9.4 DPF IN AND SCR PERKINSIN COMBINED TEMP SENSOR (1206F) ............................................... 114
9.4.1 DPF & SCR Temp Sensor Operation .................................................................................. 114
9.4.2 DPF & SCR Temp Sensor Configuration ............................................................................ 114
9.4.3 DPF & SCR Temp Sensor Installation ................................................................................ 115
9.5 IG CEM ID MODULE .................................................................................................................. 116
9.5.1 IG CEM ID Module Operation ............................................................................................ 116
9.5.2 IG CEM ID Module Configuration ..................................................................................... 116
9.5.3 IG CEM ID Module Installation .......................................................................................... 116
9.6 DOC, DPF & SCR INLET TEMPERATURE SENSORS (1204F) ....................................................... 120
9.6.1 DOC, DPF & SCR Inlet Temperature Sensor Operation .................................................... 120
9.6.2 DOC, DPF & SCR Inlet Temperature Sensor Configuration.............................................. 120
9.6.3 DOC, DPF & SCR Inlet Temperature Sensor Installation .................................................. 120
10.0 STARTING AND STOPPING THE ENGINE ....................................... 123
10.1 STARTING THE ENGINE .............................................................................................................. 123
10.2 STOPPING THE ENGINE (AND PREVENTING RESTART) ............................................................... 124
10.2.1 Ignition Keyswitch ............................................................................................................. 124
10.2.2 Battery Isolation Switches ................................................................................................. 125
10.2.3 User Defined Shutdown Switch (Remote Shutdown) ......................................................... 126
10.2.4 Delayed Engine Shutdown (1206F Only) .......................................................................... 127
10.2.4 Intake Air Shutoff Valve..................................................................................................... 127
10.2.5 Overspeed Verify Switch.................................................................................................... 128
10.2.6 Datalink stops ................................................................
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