Prkins 2800

Perkins 23/25/2800 Series
Diesel Engine Training
Perkins Product Training
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Domestics
Fire Exits
Breaks
Lunch
Toilets
Smoking
Mobile Phones
Health & Safety
Please Note
 The product training information is distributed for

informational purposes only. It is not to be construed as
creating or becoming part of Perkins Engines contractual
or warranty obligations
 The appropriate service literature, including ‘Service
Bulletins’ now available on the www.perkins.com
Secured Website, should always be the final authority and
source of information
 Wiring Diagrams/Electrical Drawings, wire numbers and
connection points may change.
Course Objectives
At the end of the course the delegates will be able to –
•Show technicians strip down techniques and the use of

special tools
•EST(Electronic Service Tool) and fault diagnosis
procedures specific to 23/25/2800
Worldwide ‘Off Road’ Legislation Today
No Legislation Requirements
Environmental Protection Agency / European Union

Regional Legislation
‘Off Road’ Emissions Legislation
Tier 0
"A" rated engines can be used in regions
without Emissions Legislation.
Tier 1
"B" rated engines are suitable for regions
with Tier 1/Stage I Emissions Legislation
Tier 2
"C" rated engines are suitable for regions
with Tier 2/Stage II Emissions Legislation.
Tier 3
"D" rated engines are suitable for regions
with Tier 3/Stage III Emissions Legislation.
‘Off Road’ Industrial - Ever Cleaner Engines
0.50
0.45
Tier 3: 56kW<75
0.40
0.35 1980’s
Tier 3: 75kW<130
PM 0.30 Particulate Matter
(g/kWh)
0.25
(PM) 0.6g/kWh
Tier 3: 130kW<560
0.20
Oxides of
0.15 Tier 4B: 56kW<560
Tier 4A: 56kW<130
Nitrogen
0.10
Tier 4A: 130kW<560 (NOx) 10.00g/kWh
0.05
0
0 1 2 3 4 5 6
NOx; NOx + HC (g/kWh)
Electronic Engine Benefits
Electronic Engine Management system gives:
 Improved Specific Fuel Consumption (SFC) through precise control

of Injection Timing and Duration.
 Machine protection under extreme operating conditions.
 Easy servicing and fault diagnostics, Electronic Service Tool, (EST)
 Exceeds emissions legislation and has a lower noise level.
 Better engine ‘responsiveness’.
 Improved reliability,engine monitoring and protection.
 Further cost savings through integration into ‘Genset' design (CAN)
 Improved torque, different torque curves available, torque ‘shaping’
 Rating changes available, Base Load, Prime, Standby, 1500/1800
 Configuration files, gives the customer flexibility, droop, etc
2306 and 2806 Engine Numbering
‘F’ Engine Family, 14.6 litre
Number of Cylinders
‘H’ Engine Family, 15.8 litre
‘J’ Engine Family, 18 litre
Country of Manufacture
FGA 06 - 1234 - U - 5678 - K

Engine Serial Number
Generator Set Build List
Year of Manufacture 03
Engine
A = TAG 1 (Turbo-Air to air charge cooled-Genset)
B = TAG 2 (Turbo-Air to air charge cooled-Genset)
D = TAG 3 (Turbo-Air to air charge cooled-Genset)
Engine Ratings - Definitions
Base Load or Continuous
 Unlimited hours usage, load factor 100%
of published base load/continuous power
 10% overload available 1 hour in 12
 Power available for continuous full load
Prime Power
 Unlimited hours usage, load factor 80%
of published prime power over 24 hours
 10% overload available 1 hour in 12
Standby (maximum)
 Power available at variable load in the event of a mains power network
failure, up to a maximum of 500 hours/year of which 300 hours may be
continuous
 No overload is permitted and the load factor is 100%
2300/2800 Series Engines
Electronic Control System, Identical
Economic Power
 Mechanically actuated Electronically controlled Unit Injection.(MEUI)
Optimum turbo-charging, excellent fuel atomisation (30,000 PSI) and
combustion, very low emissions.
Reliable Power
 Low oil usage and wear rates, high
compression ratios ensure clean rapid
starting. World Wide Support from
4000 Distributors.
Compact, Efficient Power
 Exceptional power to weight ratio,
compact size, excellent service access for
ease of maintenance
2300/2800 - Engine Component Changes
Noticeable Physical Differences - Air Filter Size
Performance Related
 Pistons
 Connecting Rods
 Liner
 Ring Pack
 Crankshaft
 Turbo
 Air Cleaner
Package Size Related
 Radiator
 Charge Cooler
 Fan and Cowling
2306/2806 Product Features
Combined primary and Integral inlet manifold Radial seal
secondary ‘Eco’ (18 litre horizontal) air filter
Fuel filters element
Fuel transfer Unique wiring

pump harness
Timing ADEM 3 ECM

Calibration With Perkins
Probe access software
hole
2306/2806 Product Features
Single stage 16 litre
high boost Composite
turbocharger top cover
Air to air
charge
Oil cooler cooler
‘Ecoplus’ full Torsional

flow vibration
oil filtration damper
Composite oil pan
2806 -18 litre Product Features
Twin exhaust Twin
manifolds turbochargers
External oil feed Large output

to the cylinder coolant pump
head
30% larger New oil filler

capacity oil tube
cooler
Aluminium sump
Rocker Assemblies
Roller Type Rockers
Second oil pressure feed to

cylinder head 18 Litre (external)
Cylinder Head
Four Valve Mono-Block Cylinder Head
Four
Forged valves
steel per
overhead cylinder
camshaft
Valve Assemblies
One of three oil

feed drillings
Valve/Injector Clearance
Establishing Number 1 TDC
Turning
tool
TDC locator
Valve
‘screw and locknut’
adjuster
Injector adjuster
Injector
trim code
Button and ‘O’ ring
Tool CH11149 Checking correct

adjustment
Machine shoulder
With Number 1 Cylinder at TDC compression stroke adjust
 Inlet valves 1,2,4
 Exh valves 1,3,5 Injectors 3,5,6

With Number 6 Cylinder at TDC compression stroke adjust
 Inlet valves 3,5,6
 Exh valves 2,4,6 Injectors 1,2,4

Clearances
 Inlet valves 0.38mm (0.015in)
 Exh Valves 0.76mm (0.030in)
 Injectors 78.0mm (3.07in) Tool N° CH11149
Injector Sleeve
 A stainless steel sleeve is used in the injector

bore to seal the coolant
 The sleeve is sealed using three ‘O’ rings.
However, combustion gases are sealed by the
injector seating on the metal in the cylinder
head bore.
 The ‘O’ ring seal fitted on the injector nozzle
provides a combustion gas seal until a carbon
dam is formed.
Injector Sleeve
A line A failed seal

contact seal results in
is attained blow by and a
hot injector
Injector Sleeve
Camshaft
Long Overlap Camshaft
Injector lobe Valve lobes
Drive gear
dowel location
Camshaft
Camshaft
Thrust Plate and Seal
Head Gasket/Spacer Plate
Oil seal
Cylinder head gasket
Coolant bobbin
Spacer plate
Oil feed O ring
‘Shim’ gasket
Exhaust Manifold
Air gap
Thermal sleeve
Cylinder Block
Open Summit Cylinder Block
Cylinder Liners
Induction Hardened Liners
Oil soaked filler band
Rubber O rings
(2806)
2306 three lower liner ‘O’ ring seals are all identical in size
Cylinder Liners
Protrusion
Pistons
2306 ‘Gallery Cooled’ Articulated Piston
Oil cooling spray cutaways
Oil cooling gallery
Pistons
2806-16 Articulated Piston
Cooling oil reservoir
Piston/Con-Rod Assembly
Tightening con-rod bolts
Pistons
2806-18 Piston
Pistons/Con-Rod Assembly
2806-18 Piston
Big end cap secured by Oil supply to small end

four bolts bearing
Piston Cooling Jets
Piston cooling jet

alignment tool
Part Number GE50004
Piston Cooling Jets
2806-18
Piston
Connecting rod
Entry to cooling
gallery
Piston cooling jet

pipe assembly
Crankshaft
Thrust washer position
Crankshaft
2806-18
Crankshaft
Grooved main bearing

fitted to block
180° thrust washers

fitted to block
Block Stiffener Plates
2300 Series
2800 Series 16 litre
Torsional Damper
Hasse and Wrede Damper
1. Housing
2. Casing
3. Inertia Ring (mass)
4. Bearings
5. Silicone Fluid
Block Stiffener Plate

2800 18 litre
Timing Gears
Coolant pump ‘Pendulum’
drive gear camshaft gear
position
Adjustable
Compound idler gear
gear
assembly
Idler gear
Crankshaft gear
Fuel transfer
Oil pump gear pump
position
Timing Gears Timing case
Pendulum Camshaft Gear
Rotating
balance
weights
Alignment
marks
Locating
dowel
Timing gear
Timing Gears
Checking Gear Backlash
Crankshaft Seals
Seal Removal/Fitting
 Gear case-split protection ring Crankshaft Seals
Oil Seal and Wear Sleeve
 Wear sleeve ‘crimp’ tool
 Must be fitted as assembly

 Must not be separated
 Must be fitted dry
Crankshaft Seals
Blue seal (rear) Green seal (front)
Induction System
2809-18
Induction System
 Air Filter Type Single medium duty paper element
 Max Air Inlet Temp 60°C (140°F)
 Initial Restriction 2.5kPa
(inlet depression new)
 Maximum Inlet Depression 6.2Kpa
(with dirty filter)
 Max Pressure Drop 14Kpa (2.03 psi)
(across charge cooler)
 Maximum Charge Air Temp 260°C (500°F)
at high (ambient conditions)
 Turbo Charger 2306 Allied Signal GT 50
2806 Borge Warner S 500
2806-18 twin Borge Warner S310
Induction System
Radial Seal Filters
Induction System
Turbochargers
Single stage ‘high boost’ turbochargers

No oil priming required
Induction System
2806-18 Turbochargers
Rear turbocharger Forward turbocharger

Exhaust gas outlet
Induction System
Air Charge Cooling/Radiator
C
A O
O
I L
R A
N
T
Induction System
2806-18
Air charge
Coolant cooling / radiator
Turbo boost air
Boost air
Coolant
Induction System
Fuel System
EUI Location
Trim code,
Below barcode
Put lever here

to remove Injector
Fuel System
Injector Seals
O ring seals
‘Sacrificial’
compression ‘O’ ring
6 hole
injector nozzle
Do not re-use seals
Fuel System
Low Pressure Fuel System
Priming pump
Venting points
Fuel return
Secondary filter
Transfer pump Fuel supply Primary filter
Fuel System
Fuel Cooler/Return
Flow =413 litres/h at 1500
Flow =457 litres/h at 1800
Return flow dependant on

engine load – Thermostat.
Fuel System Fuel System
Fuel Transfer Pump Ecoplus Fuel Filtration
Fuel System
Ecoplus Fuel Filtration Identification
Oil
Fuel Secondary Fuel primary
Fuel System
Ecoplus Fuel Filtration
Supply to head
From Temp sensor

transfer
pump
To
transfer
pump
Hand
primer
From
By-pass
Tank
valve
Return from
head
Return to Pressure Air vent

cooler Relief
Valve
Fuel System
Non-return/PRV
Lubrication System
 Type Wet sump - full flow
system
 Oil pump Gear driven - with PRV
 Capacity - total system 68 litres
 Sump maximum 60 litres
 Sump minimum 45 litres
 Lube oil temp - normal (sump) 95°C
 Lube oil temp - maximum 113°C
 Lube oil pressure - rated speed 2.7-6 bar (40-88psi)
 Lube oil pressure - min rated speed 2 bar (30psi)
 Oil pressure relief valve opening pressure 6.1 bar (88psi)
Lubrication System
Composite ‘High Capacity’ Sump
Lubrication System
Oil Pump
Lubrication System
Ecoplus Oil Filtration
Sampling
point O/P switch
Filter by-pass Cooler by-pass

valve valve
Lubrication System
2806-18
Oil cooler
assembly
Re-positioned
oil filler
tube
Re-designed
Oil filter
head
Cooling System
 Capacity of engine 20.8 Litres

 Capacity of complete system 50 Litres
 Pressure cap setting 70kPa (0.7 Bar) (10psi)
 Thermostat operating range Starts 88°C. Fully open 98°C
 Coolant pump Gear driven, centrifugal type
 Radiator Aluminium core, composite tanks
 Fan Plastic, 8 blade, pusher type.
 Maximum temperature. Top tank - 103°C
 Recommended Coolant. 50% extended life coolant,
50% de-ionised clean water.
 Coolant Life 3,000 hours or six years - max
Cooling System
Air Charge Cooling/Radiator
Composite top and bottom radiator tanks
ELC coolant to be used at all times
Cooling System
Thermostat Housing
Thermostat
Flow to radiator
Thermostat seal
By-pass
return to
coolant pump
23/25/2800 Series
Temperature and Pressure Sensors
Coolant
Temp Sensor Inlet Manifold
Air Temp Sensor
Inlet Manifold
Air Pressure
sensor
Engine Oil and

Fuel Temp Sensor Atmospheric
Pressure Sensors
Location of Calibration Probe (Plugged)
23/2800 Series
Connections and Speed/Position Sensors
110 Volt MEUI Solenoid Feeds
Cam Speed/
Position Sensor
9 Pin
Diagnostic
Connector
40 Pin Customer
Crank Connection (J3)
Speed/Position
Sensor
Electronic Control
Module
ECM “On Engine” Connector (J2)
23/25/2800 Series Electrical System
Internal Injector Harness
Jack 2 (J2)
Jack 1 (J1)
Crank Speed/Timing
36-1 TOOTH
CRANK
Coolant Temperature Sensor

GEAR
Cam Speed/Timing
Fuel Temperature Sensor
36+1 TOOTH
CAM GEAR
Inlet Manifold Sensor
Inlet Manifold Sensor Atmospheric Pressure Sensor
Engine Oil Pressure Calibration Probe
23/25/2800 ‘On Engine’ Wiring Harness
ECM
5 J2/44 Injector Common Cylinders 1 & 2

10 J2/55 Injector Cylinder 6
Injector Injector Injector Injector Injector Injector J300 P300
Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6
Atmospheric Pressure Sensor
+5V A J2/2 +5VDC Supply

Signal C J2/14 Atmospheric Pressure
Return B J2/3 Analogue Return
P203 J203
Turbo Outlet Pressure Sensor
+5V
Signal
A
C J2/40 Turbo Outlet Pressure
All fed from Jack 2 (J2) on the ECM
Return B
P200 J200
Oil Pressure Sensor
+5V A
Signal C J2/24 Oil Pressure
Return B
P201 J201
Coolant Temperature Sensor
Signal C J2/32 Coolant Temperature

Return B
J100 P100
Signal C J2/33 Fuel Temperature

Return B
J105 P105
Inlet Air Temperature Sensor
Signal C J2/35 Inlet Air Temperature

Return B J2/18 Return
J103 P103
Crankshaft Position Sensor
Signal 2 J2/48 Crank Speed Timing +

Return 1 J2/49 Crank Speed Timing -
J401 P401
Camshaft Position Sensor
Signal 2 J2/58 Cam Speed timing +

Return 1 J2/59 Cam speed timing -
J402 P402
Calibration Probe
Signal 1 J2/22 Calibration Probe +

Return 2 J2/23 Calibration Probe -
J400 P400
P2 J2
Connectors – A Reminder:
 Always use high quality connectors (Gold/Nickel Plated)

 Keep connections to a minimum
 Make sure all rubber seals are correctly fitted
 Remember…
Bad connections cause

resistance!
Resistance causes voltage

drop!
Lack of a rubber seal caused this
To happen to an ECM!
Effects of ‘Bad’ (Resistance) Connections
‘P’ Plug ‘J’ Jack
24v dc Possible ‘Bad’ Connections Lamp 24v dc
Has the same effect as….Resistances in circuit

Don’t forget all connections!
1 volt 2 volt
24v dc Resistors Lamp 19.9v dc
Don’t forget all connections! 0.1 volt 1 volt
23/25/2800 Series MEUI Injection
 Mechanically actuated by the cam shaft

 Injection controlled by the 110 Volt Solenoid
 The length of time the Solenoid is energized, and the
timing of the energization are both controlled by the
Electronic Control Module (ECM)
Mechanically Actuated
Electronically Controlled
Unit
Injector 110 Volt Solenoid
23/25/2800 Series MEUI Injector
110v dc injector solenoid
“Poppet” Valve
Shut when energised
Off
+
110v
Supply
-
Flow
‘Poppet’ Valve Principals
MEUI Injector
‘O’
Rings
Poppet Valve Fuel

de-energised chamber
Worn MEUI Injector Poppet Valves
‘O’ Rings
Wear on seat, caused by dirty fuel.

Primary Filter 10 microns,
Secondary, 2 microns
MEUI Injector Location
Injector ‘trim code’
Injector trim code
Fuel chamber
Intake
Extended life manifold
Torque setting on solenoid
coolant
Screws 2.5 Nm (22 lb in)
Electronic Control Module (ECM)
Inside the ECM is the management system that controls

 Speed Governing
 Air/Fuel Ratio
 Start/Stop Sequence
 Engine Protection Devices
 Diagnostics
 110 Volt Injector Pulses
Jack 2 (J2) all “on

engine” mounted Jack 1 (J1)
components Customer interface,
power supply etc
Basic System – A3-ECM Interactions
Inputs Control Outputs

Digital speed Adjust Voltage to operate
analogue speed diagnostic lamps
PROCESSOR
Adjust and crank terminate
PWM speed Adjust Cables/ Cables/
MEMORY relay
Connectors Connectors
Push (Engine
buttons/switches Programme) 5 volt + 8 volt
fault reset,injection Power Supplies
disable,lower/raise Power supply
digital speed, Cables/ for 5 volt Cables/ 110 Volt DC pulse
Connectors 6.5 volts and Connectors for Injectors
etc,etc
8 volts
ECM power supply, Digital output
24 v for speed control
PDL CAN J 1939

Engine Control
Electronic J 1939
Service Diagnostic
Tool Code Reader
2300/2500/2800 ‘Off Engine’ Wiring Diagram
Machine Wiring Schematic, All Options
This Wiring Supplied By OEM
Crank Terminate ECM

Notes: (Engine Running
Signal)
Outputs may be used to T J1/13 Crank Terminate Output
drive lamps or relays. C
J1- 70 Jack - Customer connection.

K
Crank Terminate should be
a relay used to disconnect Shutdown
the starter motor in OEM
panel start circuit. (ECM latched out)
J1/10 Shutdown lamp Output
G
Diagnostic lamp lights
when active system fault Action Alert
registered Action Alert Lamp Output
J1/19
Also J3 - 40 Jack - Customer connection

For full details of inputs/ U
outputs, refer to
Installation Manual
Warning
J1/20 Warning Lamp Output
P
Diagnostics
J1/31 Diagnostics Lamp Output
(Different Diagram)
K
Low Oil Pressure
J1/28 Oil Pressure Lamp Output
O
High Coolant Temp
J1/29 Coolant Temperature Lamp Output
N
Overspeed
J1/30 Overspeed Lamp Output
A
Off - Disabled - Stop
J1/62 Injection Disable
Injection Disable On - Enabled - Run U
Off
On J1/64 Shutdown Emergency Override
Critical Override K
(Disables Oil & Water shutdowns
when on)
1500
J1/56 1500/1800 rpm Select
1500/1800 1800 N
rpm Select Isoch
J1/46 Droop/Isochronous
Droop/ Droop A
Isochronous
J1/41 Fault Reset
Fault Reset Y
Enable
J1/49 Digital Speed Control Enable
Digital Speed Control Disable G
Digital J1/59 Lower Speed
Speed P
Control Lower Speed
J1/7 Raise Speed

Raise Speed O
J1/18 Digital Ground
O J1/67 Unswitched Battery Negative
B
Ground J1/5 Ground
To PWM B
Speed Control PWM J1/66 PWM Input
W
+8V J1/4 +8V
R
680R B
‘J1 Jack
5K Analogue J1/3 Analogue Ground
Speed Setting B
Potentiometer or J1/17 Analogue Speed Input
Input from Load W
Sharer/Synchroniser J1/2 +5V
680R R
J1/61 Unswitched Battery Negative
B
Charging
Alternator J1/63 Unswitched Battery Negative Main
B Battery
GRD POS J1/65 Unswitched Battery Negative Feed
Emergency B (Direct
Stop Button J1/48 Unswitched Battery Positive from
R starter/
J1/52 Unswitched Battery Positive battery)
R
J1/53 Unswitched Battery Positive
Off R
J1/70 Switched Battery Positive
Key On Y
Switch
J1/50 J1939 Data Link +
Circuit Y
Breaker (16A) J1939 Data Link -
J1/34
G
J1/42 J1939 Screen
Start Button
Starter J1/8 Perkins Data Link +
Motor G
J1/9 Perkins Data Link -
N
J1/55 Unswitched Battery Positive Power
R Supply to
J1/69 Unswitched Battery Negative Service
B Tool
- + P1 J1
Battery
9 Pin Perkins Data
24V DC J H C G F D E A B Link Connector
Some Typical Connections - ECM
Inputs Outputs
CONTROL
ECM Shutdown
Analogue
Speed Adjust
Crank Terminate
Injection Disabled
Diagnostics
Ignition Key Switch

+ 5 volt to
Sensors
-
+ - +
ECM Power Supply, -
24 v
Power Supply,
Communications Adapter 24 v
+ -
24 v J1939 PDL
23/2800 Series ECM ‘Jack’ Connections
J2 (Jack 2) J1 (Jack 1)
“On Engine” Mounted Components Customer Side
ECM Grounding
Grounding
 Always ensure the ground straps are on the Engine and
the ECM is connected to the engine block, via the ‘tag’ to
prevent EMI, Electro Magnetic Interference, affecting the
interior electronic circuits of the ECM.
Warning!
 When carrying out welding or electrostatic paint spraying,
special precautions should always be followed.
 These are listed in the Perkins Mechanical and Electronic
Installation Manual. TSL 4262, & TSL 4247.
Electronic Control Module
 Nominal battery supply voltage 18-32 volts (Max 48 for 2 mins)
 Approximately 2 - 6 amps in typical application
 10-15 mA in ‘sleep mode’ (ignition off/ECM power on)
 High Reliability.
 External connectors most vulnerable: bent ‘jacks’, J1, J2 over
tightened ECM plugs etc.
 No internal fuses or serviceable parts.
 Never replace an ECM without first connecting Electronic Service Tool
(EST) and carrying out basic diagnostics.
 The ECM is the last component you should suspect.
Raise Speed O
B
Ground J1/5 Ground
2300/2800 Series ECM Power Supplies

To PWM B
W
+8V J1/4 +8V
R
680R B
+ to Diagnostics Lamps
Speed Setting B
- to Diagnostics Lamps Analogue Speed Input
Potentiometer or J1/17
Input from Load W
680R R
B
Charging
B Battery
Emergency B (Direct
R starter/
R
Off R
Key On Y
Switch
Circuit Y
Breaker (16A) J1939 Data Link -
J1/34
G
J1/42 J1939 Screen
Start Button
Motor G
N
R Supply to
B Tool
- + P1 J1
Battery
9 Pin Perkins Data
Minimum J1 Connections, to run a
23/2800 Series
Control
ECM
Note
Injection Disabled We do suggest that
a connection is made to the
Perkins Electronic Service Tool
(EST) to allow communication
With Perkins Data Link (PDL)
Ignition Key Switch
What are the Jack connection
numbers?
+ -
ECM Power Supply,
24 v
Ignition Circuit
Ignition Key Switch
 This switch may be used for a controlled engine stop. The ignition
switch does not switch off power to the ECM. The ECM remains
connected to the battery via a fuse/circuit breaker, even when the
ignition is switched off. Can also be used to reset faults. The
Electronic Service Tool (EST) cannot communicate with the ECM
when the Ignition switch is off.
Injection Disabled
 If you want to stop the engine, use the ‘Injection Disabled’. This
allows communication with the service tool (EST) to continue.
Emergency Shut-down
 This button, interrupts the main battery power supply to the ECM and
stops the engine. Not Recommended, Don’t forget the ECM is a
computer, you do not just ‘chop off ’ the power.
23/25/2800 Series Engine Mounted Sensors
 Engine coolant temperature.

 Inlet manifold air temperature.
 Fuel temperature.
 Inlet manifold air pressure.
 Atmospheric/crankcase pressure.
 Engine oil pressure.
 Camshaft/crankshaft speed/timing.
 Calibration probe (only in special circumstances)
2300/2800 Series – Temperature Sensors
Engine Coolant Temperature Sensor
32 Signal Voltage
ECM
33 Signal Voltage
Inlet Air Temperature Sensor

35 Signal Voltage
18 0 Volts
23/2800 Series Temperature Sensor Operation
ECM
5 Volts
R
Temperature Sensor
Signal
18
Ground 0 Volts
EST Code 110
 Temperature can be viewed Coolant Temperature

Sensor
through the ECM in °C/°F via:
 J1939 CAN link
 Perkins Data Link (PDL)
 The sensor enables the cold

start strategy
 Also enables the calculation of
the fuel limit and engine timing
 Engine protection, Warning,
Action Alert and Shutdown.
EST Code 110 (Typical Temperature Sensor graph)
110-3 Signal shorted to a higher voltage or open circuit (voltage over 4.8)
4.8
Very cold Temp
Warning Temp 361 (1)
Action Alert Temp 361 (2)
Shutdown Temp 361 (3)
0.2
110-4 Signal shorted to a lower voltage (voltage under 0.2)
Temperature
Manifold Air Inlet Temperature Sensor
EST Code 174
 Temperature can be viewed Manifold Air Inlet
through the ECM in °C/°F via: Sensor
 J1939 CAN link.
 The sensor enables the cold
start strategy.
 Also enables the calculation of
the fuel limit and engine timing
 Engine protection, warning and
Action Alert.
High inlet air temperatures lead to high
exhaust temperatures, which can cause
damage to exhaust system components
(such as turbochargers and exhaust valves)
Engine Fuel Temperature Sensor
EST Code 174
Fuel Temperature
 Higher Temperature lower mass Sensor
 Lower Temperature greater mass
 Temperature can be viewed through
the ECM in °C/°F via:
 J1939 CAN link
 Also enables the calculation of the

fuel limit and engine timing.
 Protection, Warning and Action Alert.
Temperature Sensor Feeds, Harness Voltages
1 2  Voltage between 1 and 2

Coolant Temperature Sensor  Wiring harness plug connections
Intake Manifold Temperature Sensor
(check the harness to ECM)
2300/2800 Series Sensors
Different Fault Codes and How they could be Created
32
3
Intake Manifold Temperature Sensor
Break 33
ECM ‘Jack 2’
2
1 2
35
18
Fault 1………………………….
Fault 2………………………….
Fault 3………………………….
2300/2800 Series Pressure Sensors
Atmospheric/Crankcase Pressure Sensor
2 5 Volts
14 Signal Voltage
3 0 Volts
Intake Manifold Air Pressure Sensor
40 Signal Voltage
Engine Oil Pressure Sensor
24 Signal Voltage
ECM J2
23/25/2800 Series Pressure Sensor Operation
6.5 Volts
R
Pressure Sensor
5 Volt
2
3
0 Volts
Sensor ‘Fly Lead’ Main Engine Harness
ECM J2
Inlet Manifold Air Pressure Sensor
EST Code 273 - (Code also known as Turbo Boost!)
Inlet Manifold Air

 Pressure can be viewed in PSI and Kpa Pressure Sensor
through the ECM via:
 J1939 CAN link
 Used to determine mass air flow

 Enables the calculation of the correct
air/fuel ratio
 Used for smoke limiting strategy
 Range 52 Kpa Abs. 472 Kpa Abs
 Protection- Warning and Action Alert.
Inlet Manifold Air Pressure Values
2800 Kpa Gauge

1800 rpm
Full load 295 Inlet Manifold Air
1/2 Load 126 Pressure Sensor
1500 rpm
Full Load 249 263 Half TA Luft
1/2 Load 94 95
2300 Kpa Gauge

1800 rpm
Full load 205
1/2 Load 119
1500 rpm
Full Load 195 234 Half TA Luft
1/2 Load 71 71
EST Code 100
Engine Oil Pressure

Sensor
 Pressure can be viewed in PSI and
Kpa through the ECM via:
 J1939 CAN link
 Protection,Warning,Action Alert
 Protection ‘mapped’
 Range 106 Kpa to 1135 Kpa
EST Code 100 (Typical Pressure Sensor graph)
100-3 Shorted to a higher voltage or open circuit (over 4.8 volts)

4.8
Warning Pressure – E360-1
Action Alert Oil Pressure – E360-3

0.2
100-4 Signal shorted to a lower voltage (less than 0.2 volts)
Pressure
Atmospheric (Crankcase) Pressure Sensor
EST Code 274
 Pressure can be viewed in PSI and Atmospheric

Kpa, ‘absolute’ through the ECM Pressure Sensor
via:
 J1939 CAN link.
 Used to calibrate the Inlet Air and
Oil Pressure Sensors.
 With ‘Critical Override’ active, if the
sensor fails the engine will Derate
by 10%.
 Range 40 Kpa A to 116 Kpa A
2800 Series De-rate Information
 The 2306 / 2806 series engine electronic control, does not
automatically de-rate at high altitudes or high ambient
temperatures
 The de-rate information for this
engine can be obtained from
Perkins Engines
Applications Department
 These de-rate limits must
be adhered to or severe
engine damage may result
Pressure Sensor Feeds, Harness Voltages
 Voltage between A and B

 Voltage between B and C
 Voltage between A and C
B A
Atmospheric/Crankcase Pressure Sensor (DT06-3S)

Oil Pressure Sensor (DT06-3S)
Intake Manifold Air Pressure Sensor (DT06-3S)
Wiring Harness Plug Connections,

(Checks the harness to ECM)
2300/2800 Series Sensors
Different Fault Codes and How they could be Created
Atmospheric/Crankcase Pressure Sensor
1 2 5 Volts
14 Signal Voltage
3 0 Volts
Intake Manifold Air Pressure Sensor
40 Signal Voltage
2
24 Signal Voltage
3
ECM J2
Fault 1………………………….
Fault 2………………………….
Fault 3………………………….
Crankshaft Speed/Position Sensor
EST Code 190
Crankshaft Gear 36 - 1 tooth
Camshaft Speed/Position Sensor
EST Code 342 (Speed and timing Sensor 2)
Camshaft Gear 36 + 1 tooth
Checking Speed/Position Sensors
1 2  Crankshaft Sensor Resistance

between 1 and 2
Crankshaft Speed/Position
Sensor ‘fly lead’  Camshaft Sensor Resistance
between 1 and 2
1 2
 Run Engine and Measure output

AC Voltage or Frequency from
Camshaft Speed/Position
Sensor ‘fly lead’ each Sensor - one at a time
Additional Sensors/Senders
Coolant Level switch
Coolant temperature sender

CV18338/5 and adapter OE51375
Speed Sensor
CV18338 and Harness
CV18965
Oil pressure sender
CV18339/3 and adapter 3Y-2888
Additional Engine Sensors/Senders
Temperature
Switch
Oil
Coolant Level sensor
Pressure
Switch
2800 Wiring Diagram

Crank Terminate ECM
Signal)
Outputs may be used to T J1/13 Crank Terminate Output
drive lamps or relays. C K
G
J1/19
outputs, refer to
Installation Manual
Warning
P
Customer side (Jack 1)

Diagnostics
K
Low Oil Pressure
O
 Outputs - may be used to drive lamps or High Coolant Temp
N
relays. (0.3 A, 1.0 A and 1.5 A)

Overspeed
A
Crank terminate should be a relay to

Off
J1/64 Shutdown Emergency Override

Critical Override On
(Disables Oil & Water shutdowns K
when on)
1500
J1/56 1500/1800 rpm Select
monitor starter motor in the OEM panel

1500/1800 1800 N
rpm Select Isoch
Droop/ Droop A
Isochronous
J1/41 Fault Reset
Diagnostic lamp, lights when active fault

Fault Reset Y

Enable
code registered, or any of the outputs

Speed P
Control Lower Speed
J1/7 Raise Speed
are disconnected/open circuit

Raise Speed O
B
Ground J1/5 Ground
To PWM B
J1/66 PWM Input
Inputs - injection disable, RPM select,

Speed Control PWM
W
+8V J1/4 +8V
 680R
R
B
digital speed control, raise/lower,

Speed Setting B
Potentiometer or J1/17 Analogue Speed Input
Input from Load W
droop/isochronous, etc
680R R
B
Charging
B Battery
B
For full details of inputs and outputs refer

Emergency (Direct

R starter/
R
to the installation manual

Off R
Key On Y
Switch
Circuit Y
Breaker (16A)
(2800,TSL 4262. 2300, TSL 4267)

J1/34 J1939 Data Link -
G
J1/42 J1939 Screen
Start Button
G
This drawing for indication only!

Motor
N
R Supply to
B Tool
- + P1 J1
Battery
9 Pin Perkins Data
Gen-Set Desired Engine Speed/Load Control
The software in the ECM provides the flexibility to

cater for Four types of control.
 Digital Control
Typical Pressure Sensor
 Pulse Width Modulated
 Analogue Control
 CAN J1939 Control
Digital Speed/Load Control
 Enables speed control by digital load-sharing and

synchronizing equipment
 The Engine can interface directly with manual
synchronizing selector switches, relays or push buttons
 When the ECM is working on Digital Speed Control
there are three inputs that can be used.
 Digital Speed Control Enable
 Digital Speed Control Ramp Rate
 Digital Speed Control Raise/Lower
Diagnostics
K
Digital Speed/Load Control

Low Oil Pressure
O
High Coolant Temp
N
 Digital speed control (enable/disable) Overspeed Lamp Output
Overspeed
J1/30
Lower speed (pushbutton/relay contact)
A
 Off - Disabled - Stop
Raise speed (pushbutton/relay contact)
 Off
OnJ1/64 Shutdown Emergency Override
 Digital speed control ramp rate, (default 10 rpm/sec)
Critical Override
K
when on)
1500
J1/56 1500/1800 rpm Select
 This can be adjusted via the Electronic Service Tool
N
1500/1800 1800
rpm Select Isoch
Droop/Isochronous J1/46
Droop/ Droop
Speed adjustment ranges +150 –150 rpm
A
 Isochronous
J1/41 Fault Reset
Fault Reset Y
Enable
Speed P
Control Lower Speed
J1/7 Raise Speed

Raise Speed O
B
Ground J1/5 Ground
To PWM B
W Limited 2006 - All Rights Reserved
Proprietary Information of Perkins Engines Company
+8V Perkins Confidential ‘Green’ J1/4 +8V
R
2300/2800 Series PWM Speed Control
 Intended for use with a customers load-sharing unit
 The PWM signal 500 Hz, duty cycle 10-90%
 Speed adjustment –24% to +8% (0% is rated speed)
 For 50 Hz 1141 to 1621 rpm
 For 60 Hz 1369 to 1945 rpm
Note for Calibration:

If the PWM input is selected on the configuration screen but not connected
on the OEM’s side, the ECM will default the speed to 1100,
(and log a diagnostic code 91-8)
2300/2800 Series Analogue Speed Control
 Speed adjustment –10% to +10% (0% is rated speed)
 For 50 Hz 1350 to 1650 rpm
 For 60 Hz 1620 to 1980 rpm
Note for Calibration:

If the Analogue input is selected on the configuration screen but not
connected on the OEM’s side, the ECM will default the speed to 1100,
(and log a diagnostic code 1690-8)
2300/2800 Series Analogue Speed
Adjustments
1500/1800 RPM
 Resistive track 4.5V

Fault Region
potentiometer
Provide linear voltage
Voltage o/p

output (0.5v to 4.5v)
 Two series resistors
keep voltage away
from fault region 0.5V Fault Region
-10% +10%
Rated Speed
Engine Speed/Ratings Selection
 Engine Rating,Duties,Speed can be set within limits set by the torque maps
 The rating of the Engine is selectable via the EST in ‘Configuration’
 The Function will be selected at the time of manufacture or in service via the
Electronic Service Tool.
 For example: 2300 Series -

2306C-E14TAG2, 2306C-E14TAG3
The ECM has torque limit maps:
 1500 rpm prime power
 1800 rpm prime power
 1500 rpm base load - continuous
 1800 rpm base load - continuous
 1500 rpm standby maximum power
 1800 rpm standby maximum power
2800 Series Engine Protection
There are three alarm levels provided which are defined as:
 Level 1 - Operator Warning
To warn the operator or machine control system of a possible
condition within the ECM control system that requires the operators
attention.
 Level 2 – Action (called De-rate or Alert)
To inform the operator or machine control system to take action to
enable the proper control of the system (i.e. to externally de-rate or
reduce speed). This is normally used by the OEM to stop the engine.
 Level 3 – Shutdown
To inform the operator or machine control system that the ECM has
shutdown due to an operating condition reaching an unacceptable
level; or if in the ‘critical override’ condition, that the product is now
operating in a condition outside of its scope of supply and may cause
injury or be damaged in such a way as to invalidate the warranty
Warnings, Action Alert and Shutdown
Protection Device Warning Action Alert Shutdown
High Coolant Temp   
Low Oil Pressure   
Engine Over-speed   
Inlet Manifold Air Pressure  
High Inlet Manifold Air Temp  
High Fuel Temp  
There is not a warning, alert, shutdown on atmospheric – it purely logs a

diagnostic code, the diagnostic lamp comes on, the oil pressure is then
invalid and we trigger the oil pressure lamp and the shutdown
2800 Series Lamp Outputs
The ECM provides individual outputs to drive warning lamps
and/or relays to indicate each of the following fault conditions:
 Active Fault Codes (Diagnostics)

 High Coolant Temperature
 Low Oil Pressure
 Over-speed
 Level 1 (Warning)
 Level 2 (Action Alert)
 Level 3 (Shutdown)
 Lamp Outputs.
 The outputs have a maximum current value as below.
 Shutdown and Crank Terminate = 1.5 amps.
 Action Alert and Warning = 1 amp.
 Diagnostics, Oil Pressure, Coolant Temperature, Overspeed = 0.3 amps.
Customer Outputs
Crank Terminate ECM

T Signal) Crank Terminate Output
Outputs may be used to
drive lamps or relays. C J1/13
K
G
J1/19
outputs, refer to
Installation Manual
Warning
P
Diagnostics
K
Low Oil Pressure
O
High Coolant Temp
J1/29 Coolant Temperature Lamp Out
N
Overspeed
A
+ Positive - Negative Off - Disabled - Stop
Off
On
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved J1/64 Shutdown Emergency Override
Critical Override Perkins Confidential ‘Green’
K
when on)
1500
drive lamps or relays. C K
the starter motor in OEM J1/10 Shutdown lamp Output
Injection Disable/Critical Override
panel start circuit. (ECM latched out) G
J1/19
outputs, refer to
When critical override
Installation Manual
 Warning has been enabled in the service tool - the switch
Warning Lamp Output
J1/20
when 'open' allows the protection to be over P ridden, the switch when closed
enables the normal Diagnostics
protection - the diagram reads the opposite.
J1/31 TheOutput
Diagnostics Lamp idea
was that if you've enabled a feature to over K ride protection and the wire
drops off then the fail
Low Oilsafe
Pressureresults in you being able to run to destruction.
O
High Coolant Temp
 ‘Critical Override’ Not Recommended, Nignores oil pressure,
J1/29 Coolant coolant
Temperature Lamp Output
temperature, atmospheric pressure shutdowns when on
Overspeed
A
Off
On J1/64 Shutdown Emergency Override
Critical Override K
when on)
1500
J1/56 1500/1800 rpm Select
+ 24 Volts 1500/1800 1800 N
rpm Select Isoch
Droop/ Droop A
Isochronous
J1/41 Fault Reset
Fault Reset Y
Enable
2800 Series Switch Inputs
1500/1800 rpm Selection
 Switch to ground to select 1800 rpm. Enabling of this input is controlled
via the Electronic Service Tool (EST)
Droop/Isochronous
 Switch to ground for droop governing. Enabling of this switch input and
Percentage droop is set using the EST
Fault Reset
 This switch is used for clearing faults after an engine shutdown, switch to
ground for fault reset.(Faults cleared by turning the Ignition Switch off/on)
Electronic Fault Diagnostics
 Electronic Service Tool (EST)

 Electronic Diagnostic Device (EDD)
 Generic Engine Monitor (GEM)
 Diagnostic Manual TSD 3453
 Trouble Shooting Guide (TSG)
 Perkins Technical Marketing Information (PTMI)
 Workshop Manual TSD 3450
 Installation Manual TSL 4262
Electronic Fault Diagnostics
Generic Engine Monitor (GEM 2200)
Part Number 2800A003
 Compact Robust Module, connects via J1939 CAN
 Several Languages
 Analogue Gauges
 Digital Readout
 Graphs
 Active Diagnostic Codes
 Audible Alarm
 12/24 Volt Operation
J1/2 +5V
R
B
9 Pin (Deutsch)
B
J1/63
J1/65
Diagnostic
Unswitched Battery Negative
Unswitched Battery Negative
Connector Main
Battery
Feed
y B (Direct
n J1/48 Unswitched Battery Positive from
R starter/
R
J1/53 Unswitched Battery Positive Used for Diagnostic Code Reader/
Off R Generic Engine Monitor, (CAN)
J1/70 Switched Battery Positive Controller Area Network, SAE J1939
Key On Y
witch
J1/50 J1939 Data Link + Genset Control
Y
6A)
J1/34 J1939 Data Link - Screen - Unused
G
J1/42 J1939 Screen
Button
G J1/8 Perkins Data Link + Used for Electronic Service Tool
J1/9 Perkins Data Link - Perkins Data Link (PDL)
N
R Supply to
B Tool
P1 J1
9 Pin Perkins Data
J H C G F D E A B Link Connector
Electronic Engine Diagnostics
 Electronic Service Tool (EST) computer based.
 Many functions, reading of temperature, speed, pressures, etc
 Genuine network only (including some OEM’s and Dealers)
 Configuration settings, histograms, graphing, data log, etc
 Installing/downloading ‘flash files’ and full engine diagnostics.
 Electronic Diagnostic Device, (EDD).

 Reads J 1939 Codes, available to anyone.
 Not a substitute for the EST.
 Ability to control Engine Speed Remotely
Electronic Service Tool (EST)
 An element of TIPSS
 The Integrated Product Support Solution
 Common for all future Perkins Engines
 Hardware and software required
 Computer/Communications adapter
 Annual subscription
 Restricted to genuine networks
Diagnostic Fault Codes
Engine coolant temperature
Active Diagnostic Codes
 Any fault that is currently
‘Active’ on the engine. 110 3
Logged Diagnostic Codes
 Faults that have occurred,
‘Logged’ and been repaired.
Logged Event Codes CID FMI
 Problems ‘Events’ that could Component/circuit Failure mode
cause permanent damage identifier identifier
E 361-1 High Engine Coolant Temperature (Warning)

E 361-2 High Engine Coolant Temperature (Action Alert)
E 361-3 High Engine Coolant Temperature (Shutdown)
23/25/2800 Speed/Timing Calibration
 This Procedure is only necessary if the Diagnostic Code is present:

 The engine may run rough, emit white smoke or they may be no
noticeable performance effects
261-13 Engine Timing Calibration Required
 If the ECM has been replaced and you are unable to take data from
existing ECM, or if repairs have been completed to the engine drive
train or possibly replaced Speed/Timing sensors
 The engine must be running at 1100 rpm for ECM calibration.
Timing Calibration Probe Installation
1mm (0.040in)
The probe measures the angular position of the crankshaft and compares this
to the measurement coming from the Camshaft Speed/Timing Sensor.
The ECM then makes a correction or calibration if necessary
ECM Timing Calibration Location Position
Calibration slot
ECM Calibration ref

position
Distance between
TDC position and
ECM Calibration
position approx
100/125 mm
Crankcase TDC Ref Point

Crankshaft TDC Ref Position Crankcase Calibration access blank plug
2300/2800 Series Immersion Heater
 110V/240V immersion heaters and thermostat. Rated at
1500W, thermostat temperature range of 38 to 49°C
Route harness to avoid heat Thermostat
from the exhaust Sensor
manifold/turbocharger
Immersion
Heater
Element
Position
Immersion Heater Connect to: 110/240

Element Volt Power Supply
2300/2800 Series Cold Start Mode
Timing Advance
 The ECM provides automatic timing advance in cold weather to
compensate for the increased ignition delay of cold fuel and cold air
 Several conditions exist in cold engines which cause increased white
smoke from incomplete combustion
Conditions
 Triggered below 18 Deg C
 The inlet air is cold.
 The fuel is cold and does not ignite as easily
 Longer Ignition delay.
 The piston, cylinder wall and head are cold.
 The cold fuel does not burn as rapidly
Make sure ‘Overspeed’ is
2800 Series Governor Stability - configured with the EST
 Establish how much governor instability (rpm above and below rated speed)
 (Increasing governor proportional gain - hunt duration will Increase)
 (Decreasing governor proportional gain - hunt duration will Decrease)
 Adjustments
 20 rpm below rated speed - adjust min stability and reduce proportional gain
 20 rpm above rated speed - adjust max stability and reduce proportional gain
 Typical 2806
 Governor proportional gain - 26,214 (range 1 - 39999)
 Governor maximum stability factor - 3146
 Governor minimum stability factor - 1573
 Type in value ‘O’ and configuration will return to its default value
Note:
Altering values can affect steady state and transient speed/response
If you need Technical advice contact our dedicated Engineers
Use the Request Form
on the Perkins Secured Internet
http://www.perkins.com/perkins/cda/technicalSupportRequest/1,4077,,00.html
Or
Send an email to
technical_help@perkins.com
For URGENT queries only, telephone +44 (0)1733 582858
23/25/2800 Series
End of Course Questions
1. What reference voltage do we use to power the analogue speed

adjustment, what are the ‘Jack’ numbers?
2. What application could use ‘Critical Override?
3. What would happen if I disconnected the oil pressure sensor?
4. What is the description for these fault codes: 110-3/100-4?
5. What could be the cause of the above faults?
6. What is the preferred method of stopping the engine?
7. Name the two sensors that monitor engine speed/position?
8. Will the engine still start with one speed/position sensor
disconnected?
23/25/2800 Series
End of Course Questions (cont/d)
9. What does PWM stand for?

10. What type of Thermistor is in the temperature sensors?
11. What are the ‘Jack’ connections for the ECM power supply?
12. What voltage would I expect between ‘Jacks A,B,C,on the harness
feeding the pressure sensors?
13. What voltage is expected across the temperature sensor ‘plug’ with
the sensor disconnected?
14. Why are diodes fitted across relays in an electronic engine?
15. A pressure sensor power supply open circuit will create which code?
16. How can I achieve 1100 RPM to calibrate the timing?

Prkins 2800

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Perkins 23/25/2800 Series

Diesel Engine Training

Perkins Product Training

 The product training information is distributed for

At the end of the course the delegates will be able to –

•Show technicians strip down techniques and the use of

Environmental Protection Agency / European Union

NOx; NOx + HC (g/kWh)

 Improved Specific Fuel Consumption (SFC) through precise control

FGA 06 - 1234 - U - 5678 - K

Fuel transfer Unique wiring

Timing ADEM 3 ECM

‘Ecoplus’ full Torsional

Composite oil pan

External oil feed Large output

30% larger New oil filler

Second oil pressure feed to

One of three oil

Button and ‘O’ ring

Tool CH11149 Checking correct

 Exh valves 1,3,5 Injectors 3,5,6

 Exh valves 2,4,6 Injectors 1,2,4

 Exh Valves 0.76mm (0.030in)

 Injectors 78.0mm (3.07in) Tool N° CH11149

 A stainless steel sleeve is used in the injector

A line A failed seal

Injector lobe Valve lobes

Cylinder head gasket

Oil feed O ring

Oil soaked filler band

Oil cooling spray cutaways

Oil cooling gallery

Cooling oil reservoir

Tightening con-rod bolts

Big end cap secured by Oil supply to small end

Piston cooling jet

Piston cooling jet

Grooved main bearing

180° thrust washers

2800 Series 16 litre

Block Stiffener Plate

 Must be fitted as assembly

Blue seal (rear) Green seal (front)

Single stage ‘high boost’ turbochargers

Rear turbocharger Forward turbocharger

Put lever here

Do not re-use seals

Flow =413 litres/h at 1500

Flow =457 litres/h at 1800

Return flow dependant on

From Temp sensor

Return to Pressure Air vent

Filter by-pass Cooler by-pass

 Capacity of engine 20.8 Litres

Composite top and bottom radiator tanks

ELC coolant to be used at all times

Engine Oil and

Coolant Temperature Sensor

Inlet Manifold Sensor

Inlet Manifold Sensor Atmospheric Pressure Sensor

Engine Oil Pressure Calibration Probe

5 J2/44 Injector Common Cylinders 1 & 2

Atmospheric Pressure Sensor