Perkins 2800 Series

Mode ls 2806C-E16   and  2806C-E18

DIAGNOSTIC MANUAL

6 cylinder turbocharged diesel engine

Publica tion TS D 3453E, Is sue   3.

© Proprie tary informa tion of P erkins Engine  s Compa  ny Limited, a ll rights reserved.

The  informa tion is corre ct a t the  time of print.

Publishe d in J une  2004 by Te  chnica l Publica tions ,

Perkins Engine  s Compa  ny Limited, Tixa  ll Road, S tafford, S T16 3UB, Engla  nd

Diagnos tic Manua l, TSD 3453E, Is  sue  3

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Chapters

1    General information

2    Electronic system overview

3    Programming parameters

4    Fault diagnosis

5    Special Tools

The following pages contain a detailed table of contents

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Contents

1 General information

Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1

Safety precautions  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...2

Glossary of terms  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3

2 Electronic system overview

System operation .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9

Electronic controls  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9

Engine governor  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9

Timing considerations .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9

Fuel injection . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .10

Engine monitoring   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .11

Fuel temperature monitoring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .11

Self diagnostics   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .11

Effect of diagnostic codes on engine performance  .. ... ... ... ... ... ... ... ... ... ... ... ... .12

Current totals stored in the ECM . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .12

Programmable parameters  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .12

Passwords . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13

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Engine component diagram  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  14

OEM connection diagram  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  15

Sensor and connector location diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  16

Engine wiring diagram .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  17

Machine wiring diagram (all options)  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  18

Electrical connectors and functions  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  19

Colour codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  19

Service tools and diagnostics .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  20

3 Programming parameters

Connecting the TIPSS-EST ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  21

Passwords .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  23

Programming a new ECM  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  24

Programming an ECM using flash programming ... ... ... ... ... ... ... ... ... ... ... ... ... ...  27

ECM date/time clock .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  28

ECM diagnostic clock  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  29

Injector codes   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  29

TIPSS-EST cylinder cut-out test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  29

Programming parameters . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  29

System configuration parameters  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  30

Customer specified parameters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  32

4 Fault diagnosis

Introduction  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  35

Diagnostic procedures without a diagnostic fault code

General information  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  36

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Diagnostic symptoms

Test 1 - Engine will not crank   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .37

Test 2 - Engine cranks but will not start   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .38

Test 3 - Engine misfires, runs rough or is unstable ... ... ... ... ... ... ... ... ... ... ... ... ... ... .39

Test 4 - Low power/poor or no response to throttle ... ... ... ... ... ... ... ... ... ... ... ... ... ... .40

Test 5 - Intermittent engine shutdowns  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .41

Test 6 - Intermittent low power or power cut-outs  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .42

Test 7 - Electronic service tool will not communicate with the ECM  . ... ... ... ... ... ... ... .43

Test 8 - ECM will not accept factory passwords  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .44

Test 9 - Excessive black smoke  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .45

Test 10 - Excessive white smoke .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .46

Test 11 - Excessive blue smoke  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .47

Test 12 - Engine cannot reach correct rev/min  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .48

Test 13 - Poor acceleration or response  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .49

Test 14 - Poor fuel consumption  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .50

Test 15 - Too much vibration . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .51

Test 16 - Noise coming from cylinder  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .52

Test 17 - Excessive valve clearance . ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... .53

Test 18 - Valve rotocoil or spring lock is free   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .54

Test 19 - Mechanical noise (knock) in engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .55

Test 20 - Oil in cooling system  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .56

Test 21 - Fuel in cooling system  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .57

Test 22 - Coolant in lubricating oil . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .58

Test 23 - Fuel dilution of lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .59

Test 24 - Engine has early wear  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .60

Test 25 - Engine has low oil pressure  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .61

Test 26 - Engine uses too much lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .62

Test 27 - Engine coolant is too hot  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .63

Test 28 - Oil at the exhaust  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .64

Test 29 - Engine has a fuel supply problem .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .65

Test 30 - Indicator lamp not functioning correctly .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .66

Test 31 - Inlet air manifold temperature is too high ... ... ... ... ... ... ... ... ... ... ... ... ... ... .67

Test 32 - Engine has a high fuel temperature  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .68

Diagnostic procedures with an event code

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .69

Event codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .69

Diagnostic tests

Test 33 - High intake manifold pressure  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .70

Test 34 - Low oil pressure . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... .71

Test 35 - High coolant temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .72

Test 36 - Engine overspeed  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .73

Test 37 - High fuel temperature . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .74

Test 38 - High intake manifold air temperature  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .75

Diagnostic procedures with a diagnostic fault code

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General information  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  76

Diagnostic codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  76

Diagnostic terminology . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  78

Connectors . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  79

Diagnostic tests

Test 39 - Inspecting electrical connectors .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  82

Test 40 - Electrical power supply to the ECM  ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... 88

Test 41 - Analogue sensor open or short circuit test  . ... ... ... ... ... ... ... ... ... ... ... ... ...  91

Test 42 - ECM Status indicator output circuit test .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101

Test 43 - +5 V Sensor voltage supply circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107

Test 44 - PWM desired speed setting circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 112

Test 45 - Perkins Data Link circuit test  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118

Test 46 - Engine speed/timing circuit test .. ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... .. 126

Test 47 - Engine speed/timing calibration .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 134

Test 48 - Injector solenoids circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 138

Test 49 - Analogue sensor abnormal test .. ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... .. 146

5 Special tools

Required service tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149

Optional service tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 150

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General information

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Introduction

The 2300 and 2800 Series industrial diesel engines are the latest development from Perkins Engines

Company Limited, a world leader in the design and manufacture of high performance diesel engines.

Read and remember the "Safety precautions" on page 2. They are given for your protection and must be

applied at all times.

Danger is indicated in the text by two methods:

Warning! This indicates that there is a possible danger to the person.

Caution: This indicates that there is a possible danger to the engine.

Note: Is used where the information is important, but there is not a danger.

Ensure that all adjustments and repairs are done by personnel who have had the correct training.

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Safety precautions

These safety precautions are important. Reference must also be made to the local regulations in the country

of operation.

z   Only use these engines in the type of application for which they have been designed.

z   Do not change the specification of the engine.

z   Do not smoke when you put fuel in the tank.

z   Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a

safe place.

z   Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).

z   Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;

even then extreme caution must be used to prevent injury).

z   Do not make adjustments that you do not understand.

z   Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.

z   Other persons must be kept at a safe distance while the engine or equipment is in operation.

z   Do not permit loose clothing or long hair near moving parts.

z   Keep away from moving parts during engine operation.

Warning! Some moving parts cannot be seen clearly while the engine runs.

z   Do not operate the engine if a safety guard has been removed.

z   Do not remove the filler cap of the cooling system while the engine is hot and while the coolant is under

pressure, because dangerous hot coolant can be discharged.

z   Do not use salt water or any other coolant which can cause corrosion in the closed coolant circuit.

z   Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the

gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially

to the eyes.

z   Disconnect the battery terminals before a repair is made to the electrical system. Always disconnect the

negative terminal first.

z   Only one person must control the engine.

z   Ensure that the engine is operated only from the control panel or from the operator’s position.

z   If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.

z   Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.

Protect your hands with gloves or a special solution to protect the skin.

z   Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated

with oil into the pockets.

z   Discard used lubricating oil in a safe place to prevent contamination.

z   The combustible material of some components of the engine (for example certain seals) can become

extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with

the eyes.

z   Fuel and oil pipes MUST be inspected for cracks or damage before they are fitted to the engine.

z   Fit only genuine Perkins parts.

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Glossary of terms

Active diagnostic code

Describes a condition that is currently present to alert the operator or service technician of an abnormal engine

operation parameter. See also Diagnostic fault code.

Aftermarket device

A device or an accessory that is installed by the customer or OEM after the engine has been delivered.

Alternating current (AC)

The direction of current flow changes (alternates) regularly and constantly in a circuit.

Atmospheric pressure sensor

Analogue sensor generates a signal proportional to atmospheric (barometric) air pressure in the crankcase

and sends a signal to the ECM.

Before top center (BTC)

The 180° of crankshaft rotation before the piston reaches the very top of its travel (normal direction of rotation).

Intake manifold pressure sensor

This sensor measures inlet manifold air pressure (boost pressure) and sends a signal to the ECM.

Bypass circuit

A circuit, usually temporary, to substitute for an existing circuit, typically for test purposes.

Calibration

An electronic adjustment of a sensor signal.

Perkins engine monitoring

The part of the Perkins Electronic Engine Control that monitors coolant temperature, oil pressure, intake

manifold air temperature and coolant level to alert the operator of detected problems. The coolant temperature,

intake manifold air temperature, and oil pressure sensors are supplied by Perkins and monitored by the ECM.

Aftermarket engine monitoring systems do not interface with the Perkins Electronic Engine Control.

Check engine lamp

Sometimes referred to as the diagnostic lamp, it is used to alert the operator of the presence of an active event.

Code

Refer to diagnostic fault code and diagnostic event code.

Cold mode

A mode of engine operation where the timing is retarded for engine protection, reduced smoke emissions and

faster warm up time.

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Component identifier (CID)

The CID is a number that identifies the specific component of the electronic control system that has

experienced a diagnostic code. This is part of the PDL (Perkins Data Link).

Communication adapter

The communication adapter provides a communication link between the ECM and an electronic service tool.

Coolant temperature sensor

This sensor detects the engine coolant temperature for Cold Mode operation and Perkins Engine Monitoring.

Crankshaft position sensor

A sensor that measures the crankshaft position, the direction of rotation, and engine rev/min and sends signals

to the ECM.

Customer specified parameter

A parameter value that can be changed and whose value is set by the customer. These parameters can be

protected by customer passwords.

Desired rev/min

An input to the electronic governor in the ECM. The electronic governor uses inputs from the crankshaft

position sensor and customer parameters to determine 'desired rev/min'.

Diagnostic event code

These codes indicate an event that describes an abnormal engine condition such as a shutdown occurrence.

These , codes are not necessarily (or usually) an indication of problems within the electronic system.

Diagnostic fault code

Sometimes referred to as a "fault code". These codes indicate an electronic system malfunction or problem

with the engine electronic system.

Diagnostic lamp

Sometimes referred to as the "engine check lamp", it is used to alert the operator of the presence of an active

diagnostic code.

Direct current (DC)

The type of current where the direction of current flow is consistently in one direction.

Duty cycle

Refer to pulse width modulation.

Engine control module (ECM)

The engine control computer that provides power to the engine electronics. It accepts inputs that monitor and

outputs that control or change to act as a governor to control engine rev/min.

Electronically controlled unit injector

The injection pump which is a mechanically actuated, electronically controlled unit injector, combining the

pumping, electronic fuel metering and injecting elements in a single unit.

Electronic engine control

The complete electronic system that monitors and controls the engine operation under all conditions.

Engine speed/timing sensor

Provides a variable amplitude and pulse width modulated signal to the ECM, which the ECM interprets as

crankshaft position and engine speed.

Estimated dynamic timing

The ECM's estimation of actual injection timing.

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Failure mode identifier (FMI)

Type of failure that has been experienced by the component (adopted from the SAE standard practice of J1587

diagnostics).

Flash programming

A method of programming or updating an ECM with an electronic service tool over the data link instead of

replacing components.

Fuel position

An internal signal within the ECM, from the electronic governor to the fuel injection control. It is based on

desired rev/min, FRC fuel limit, rated fuel limit, and the actual engine rev/min.

Fuel ratio control (FRC)

A limit based on control of the fuel to air ratio and used for emission control purposes. When the ECM senses

a higher intake manifold pressure (more air into cylinder), it increases the FRC fuel limit (allows more fuel into

cylinder).

Fuel temperature sensor

This sensor detects the fuel temperature. The ECM monitors the fuel temperature and adjusts the calculated

fuel rate accordingly.

Full load setting (FLS)

Number representing fuel system adjustment made at the factory to "fine tune" the fuel system maximum fuel

delivery. Correct value for this parameter is stamped on the engine information ratings plate. This parameter

must be programmed or a 268-02 Check Programmable Parameters diagnostic code will be generated.

Full torque setting (FTS)

Similar to the Full Load Setting. This parameter must be programmed or a 268-02 Check Programmable

Parameters diagnostic code will be generated.

Harness

The wiring loom that connects all components of the electronic system.

Hertz (Hz)

Measure of electrical frequency in cycles per second.

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Histogram

A bar graph indicating the relative frequency of engine operation in specific operating ranges.

Injector codes

Four digit code etched on the tappet or stamped on individual injectors of the electronic unit injectors.

Intake manifold air temperature sensor

This sensor detects the intake manifold air temperature. The ECM monitors the inlet air temperature and

coolant temperature to adjust injection timing.

Integrated electronic controls

The engine is designed with the electronic controls as a necessary part of the system. The engine will not

operate without the electronic controls.

J1939 data link

An SAE (Society of Automotive Engineers) standard data link used to communicate between the electronic

engine, the transmission, and/or powertrain controls.

Logged diagnostic codes

Describes codes which are stored in memory. These codes are meant to be an indicator of possible causes

for intermittent problems. Refer to diagnostic fault code.

Oil pressure sensor

This sensor measures engine oil pressure and sends a signal to the ECM as part of Perkins Engine Monitoring.

Open circuit

Condition where an electrical wire or connection is broken or a switch is open, so that the signal or the supply

voltage can no longer reach its intended destination.

Original equipment manufacturer (OEM)

The manufacturer of equipment in which a Perkins engine is installed.

Parameter

A programmable value or limit which determines the characteristics or behaviour of the engine.

Parameter identifier (PID)

Two or three digit code which is assigned to each component in order to identify data via the data link to the

ECM.

Password

A group of numeric or alphanumeric characters that is designed to restrict access to parameters. The

electronic system requires correct passwords in order to change customer specified parameters (customer

passwords) or certain engine specifications (factory passwords). Passwords are also required to clear certain

diagnostic codes.

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Pulse width modulation (PWM)

A signal consisting of variable width pulses at fixed intervals, whose ratio of "TIME ON" versus total "TIME

OFF" can be varied (also referred to as "duty cycle").

ON

10% Duty Cycle

OFF

ON

50% Duty Cycle

OFF

ON

90% Duty Cycle

OFF

TIME

Example of Pulse Width Modulation (PWM) Signals

Rated fuel limit

Indicates the maximum allowable fuel position (longest injection pulse). It will produce rated power for this

engine configuration.

Reference voltage

A regulated, unchanging voltage supplied by the ECM to a sensor. The reference voltage is used by the sensor

to generate a signal voltage.

Sensor

A device that is used to detect and convert a change in pressure, temperature, or mechanical movement into

an electrical signal.

Short circuit

A condition where an electrical circuit is unintentionally connected to an undesirable point. An example of a

short circuit is a wire which rubs against an engine frame until it eventually wears off its insulation and makes

electrical contact with the frame.

Subsystem

A part of the electronic system that relates to a particular function.

Supply voltage

A constant voltage supplied to a component to provide electrical power for its operation. It may be generated

by the ECM or may be battery voltage supplied by the equipment wiring.

System configuration parameters

Parameters that affect the power rating family or emissions.

"T" harness

A test harness that is designed to connect into the engine harness which allows normal circuit operation while

providing a breakout or "T" in order to measure signals.

Timing calibration

The adjustment of an electrical signal as a means of correcting the timing error between the crankshaft and

crankshaft position sensors.

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TIPSS-EST

A service tool software program to run on a personal computer (PC).

Total tattletale

Total number of changes to all the customer specified parameters stored in the ECM.

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Electronic system overview

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System operation

The 2300 and 2800 Series industrial diesel engines are designed for electronic control. The injection pump,

fuel lines and nozzles used in mechanical engines have been replaced with an electronic unit injector in each

cylinder. A solenoid on each injector controls the amount of fuel that is delivered by the injector. An Engine

Control Module (ECM) sends a signal to each injector solenoid in order to provide complete control of the

engine.

Electronic controls

The electronic system consists of the Engine Control Module (ECM), the engine sensors and the OEM

interface. The ECM is the computer which controls the engine and contains the software which controls how

the ECM behaves and stores the operating maps that define power, rev/min, etc.

Engine governor

The electronic controls on the engine serve as the engine governor, determining when and how much fuel to

deliver to the cylinders based on the actual and desired conditions at any given time.

The ECM uses one of three possible speed control inputs to determine the desired engine speed and

compares this to the actual engine speed determined through the crankshaft position sensor. If the desired

engine speed is greater than the actual engine speed, more fuel is injected in order to increase engine speed.

Timing considerations

Once the ECM has determined how much fuel is required, it must next determine when to inject the fuel.

Injection timing is determined by the ECM after considering input from the following components:

z   Coolant temperature sensor

z   Intake manifold air temperature sensor

z   Atmospheric pressure sensor

z   Intake manifold pressure sensor

The ECM determines where top centre on cylinder number one is located from the engine camshaft position

sensor signal. The ECM decides when injection should occur relative to top centre and provides the signal to

the injector at the desired time. The ECM adjusts timing for the best engine performance, fuel economy and

white smoke control.

Note: Actual or desired timing cannot be viewed with the TIPSS-EST service tool.

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Fuel injection

The ECM controls the amount of fuel injected by varying the signals to the injectors. The injectors will pump

fuel only if the injector solenoid is energized. The ECM sends a high voltage signal to energize the solenoid.

By controlling the timing and duration of the high voltage signal the ECM can control injection timing and the

amount of fuel that is injected.

The software inside the ECM sets certain limits on the amount of fuel that can be injected. The fuel limit is a

limit based on boost pressure to control the air/fuel ratio for control of emissions. When the ECM senses a

higher boost pressure (more air into cylinder) it increases the fuel limit (allows more fuel into cylinder).

The Rated Fuel Limit is a limit that is based on the power rating of the engine and engine rev/min. It is similar

to the rack stops and torque spring on a mechanically governed engine. It provides power and torque curves

for a specific engine family and rating.

Note: All of these limits are determined at the factory in the ECM software and cannot be changed.

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Engine monitoring

Perkins provides a factory installed engine monitoring system. The Perkins engine monitoring system monitors

the following parameters:

z   Engine oil pressure

z   Coolant temperature

z   Intake manifold air temperature

z   Engine speed

z   Boost pressure

z   Fuel temperature

The Perkins engine monitoring system has three levels of operation, WARNING, ACTION ALERT and

SHUTDOWN as described below.

Perkins engine monitoring WARNING operation

In the WARNING condition the ECM causes the Warning lamp to turn ON to indicate a problem has been

detected by the Engine Monitoring System. No further ECM or engine action occurs.

Perkins engine monitoring ACTION ALERT operation

In the ACTION ALERT condition the ECM begins by activating the Action Alert lamp ON to indicate a problem

has been detected by the Engine Monitoring System. This is also normally wired to cause a shutdown via the

OEM control panel.

Perkins engine monitoring SHUTDOWN operation

If the fault reaches the SHUTDOWN condition the ECM activates the shutdown lamp and unless the engine is

in CRITICAL OVERRIDE condition, the engine will shutdown.

Fuel temperature monitoring

The fuel temperature sensor monitors the fuel temperature, adjusting the ECM calculated fuel rate to

compensate for fuel temperature changes and to adjust the fuel rate for constant power. The sensor is also

used to warn the operator of excessive fuel temperature with a diagnostic event code because excessive fuel

temperatures can adversely affect engine performance.

Self diagnostics

The electronic system has the ability to diagnose problems. When a problem is detected, a diagnostic code is

generated and stored in permanent memory (logged) in the ECM. The diagnostic lamp is also activated.

When diagnostic codes occur, the diagnostic codes are referred to as Active diagnostic codes. They indicate

that a problem of some kind currently exists.

Diagnostic codes that are stored in memory are called Logged diagnostic codes. Since the problem may have

been temporary, or may have been repaired since the problem was logged, logged codes do not necessarily

mean that something needs to be repaired. They are instead meant to be an indication of probable causes for

intermittent problems.

Diagnostic codes that identify operating conditions outside the normal operating range are called Events.

Event codes are not typically an indication of an electronic system problem.

Note: Some of the diagnostic codes require passwords to clear.

Diagnostic Manual, TSD 3453E, Issue 3

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This document has been printed from SPI². Not for Resale

2

2800 Series

Effect of diagnostic codes on engine performance

The discussion on engine monitoring mentions that the diagnostic lamp activates when a specific condition

exists. When the ECM detects an engine problem, it generates an active diagnostic code and also logs the

diagnostic code in order to indicate when, and if appropriate, how many times the problem occurred. There are

two types of diagnostic codes, Fault codes and Event codes.

Diagnostic fault codes

These are provided in order to indicate that an electrical or electronic problem has been detected by the ECM.

In some cases the engine performance can be affected when the condition causing the code exists. More

frequently, however, no difference in the engine performance can be detected.

Diagnostic event codes

Diagnostic event codes are used to indicate that some operational problem has been detected in the engine

by the ECM. This usually does not indicate an electronic malfunction.

The ECM also provides an ECM clock with date/time to date and time stamp the following critical event codes:

z   360-3 Low oil pressure Shutdown

z   361-3 High coolant temperature Shutdown

For a listing all of the diagnostic fault codes, along with the page number where details regarding the cause,

performance effect, and diagnosis of the code can be located, refer to "Diagnostic code quick reference" on

page 80.

Current totals stored in the ECM

The ECM maintains engine total data for the following parameters:

Total time

The total time is the engine's operating hours. This does not include operating time when the ECM is powered

ON but the engine is not running.

Programmable parameters

Certain parameters affecting engine operation may be changed with the TIPSS-EST service tool. The

parameters are stored in the ECM, and are protected from unauthorized changes by passwords. These

parameters are either system configuration parameters or customer parameters.

System configuration parameters

These are set at the factory and affect emissions or power ratings within an engine family. Factory passwords

must be obtained and used to change the system configuration parameters.

Customer parameters

These are variable and can be used to tailor the engine to customer requirements within the limits set by the

factory and Perkins engine monitoring operation. Customer passwords may be required to change customer

parameters.

Caution: Some of the parameters may affect engine operation. Without adequate training, these parameters

may lead to power or performance complaints even when the engine is performing to specification.

Refer to "Programming parameters" on page 29 for further information.