Perkins ENGINE 1200F Series Models MT, MU, MV, MW, BM and BN ELECTRONIC APPLICATION & INSTALLATION MANUAL

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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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Perkins ENGINE 1200F Series Models MT, MU, MV, MW, BM and BN ELECTRONIC APPLICATION & INSTALLATION MANUAL
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