2800 Electronic Mech Jan07

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
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Exits
Breaks
Lunch
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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: 56kW<75
0.40
1980s
0.35
PM
(g/kWh)
Particulate Matter
(PM) 0.6g/kWh
Tier 3: 75kW<130
0.30
0.25
Tier 3: 130kW<560
0.20
0.15
Oxides of
Nitrogen
(NOx) 10.00g/kWh
Tier 4B: 56kW<560

Tier 4A: 56kW<130
0.10
Tier 4A: 130kW<560
0.05
0
0
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
Engine
Build List
Year of Manufacture 03
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
secondary Eco
Fuel filters
Integral inlet manifold

(18 litre horizontal)
Fuel transfer
pump
Radial seal
air filter
element
Unique wiring
harness
Timing
Calibration
Probe access
hole
ADEM 3 ECM
With Perkins
software
2306/2806 Product Features

Single stage
high boost
turbocharger
16 litre
Composite
top cover
Oil cooler
Air to air
charge
cooler
Ecoplus full
flow
oil filtration
Torsional
vibration
damper
Composite oil pan
2806 -18 litre Product Features

Twin
turbochargers
Twin exhaust
manifolds
External oil feed

to the cylinder
head
Large output
coolant pump
30% larger
capacity oil
cooler
New oil filler

tube
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
valves
per
cylinder
Forged
steel
overhead
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
contact seal
is attained
A failed seal
results in
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

four bolts
Oil supply to small end

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.
2.
3.
4.
5.
Housing
Casing
Inertia Ring (mass)
Bearings
Silicone Fluid
Block Stiffener Plate

2800 18 litre
Timing Gears
Coolant pump
drive gear
position
Pendulum
camshaft gear
Adjustable
idler gear
Compound
gear
assembly
Idler gear
Crankshaft gear
Fuel transfer
pump
Oil pump gear

position
Timing Gears
Pendulum Camshaft Gear
Timing case
Rotating
balance
weights
Locating
dowel
Alignment
marks
Timing gear
Timing Gears
Checking Gear Backlash
Crankshaft Seals
Seal Removal/Fitting
Crankshaft Seals
Gear case-split protection ring
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
60C (140F)
Initial Restriction
(inlet depression new)
2.5kPa
Maximum Inlet Depression

(with dirty filter)
6.2Kpa
Max Pressure Drop

(across charge cooler)
14Kpa (2.03 psi)
Maximum Charge Air Temp

at high (ambient conditions)
260C (500F)
Turbo Charger
2806 Borge Warner S 500
2306 Allied Signal GT 50

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
Exhaust gas outlet
Forward turbocharger
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 Transfer Pump
Fuel System
Ecoplus Fuel Filtration
Fuel System
Ecoplus Fuel Filtration Identification
Oil
Fuel Secondary
Fuel primary
Fuel System
Ecoplus Fuel Filtration

From
transfer
pump
Supply to head
Temp sensor
To
transfer
pump
Hand
primer
By-pass
valve
From
Tank
Return from
head
Return to
cooler
Pressure
Relief
Valve
Air vent
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)
95C
Lube oil temp - maximum
113C
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
valve
Cooler by-pass
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 88C. Fully open 98C
Coolant pump
Gear driven, centrifugal type
Radiator
Aluminium core, composite tanks
Fan
Plastic, 8 blade, pusher type.
Maximum temperature.
Top tank - 103C
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
Fuel Temp Sensor

Location of Calibration Probe (Plugged)
Engine Oil and

Atmospheric
Pressure Sensors
23/2800 Series
Connections and Speed/Position Sensors

110 Volt MEUI Solenoid Feeds
Cam Speed/
Position Sensor
9 Pin
Diagnostic
Connector
40 Pin Customer
Connection (J3)
Crank
Speed/Position
Sensor
ECM On Engine Connector (J2)
Electronic Control
Module
23/25/2800 Series Electrical System

Internal Injector Harness
Jack 2 (J2)
Jack 1 (J1)
Crank Speed/Timing
36-1 TOOTH
CRANK
GEAR
Coolant Temperature Sensor

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
7
6
10
3
11
2
12
1
I n je c t o r
C yl 1
I n je c t o r
C yl 2
I n je c t o r
C yl 3
I n je c t o r
C yl 4
I n je c t o r
C yl 5
I n je c t o r
C yl 6
J 2 /4 4
J 2 /4 5
J 2 /4 6
J 2 /5 5
J 2 /5 4
J 2 /3 9
J 2 /3 8
J 2 /3 7
J 2 /3 6
In
In
In
In
In
In
In
In
In
je c to
je c to
je c to
je c to
je c to
je c to
je c to
je c to
je c to
r
r
r
r
r
r
r
r
r
C
C
C
C
C
C
C
C
C
om m
om m
om m
y lin d
y lin d
y lin d
y lin d
y lin d
y lin d
o n C y lin d e r s 1 & 2
er 6
er 5
er 4
er 3
er 2
er 1
J 2 /2
J 2 /1 4
J 2 /3
+ 5 V D C S u p p ly
A tm o s p h e r ic P r e s s u r e
A n a lo g u e R e t u r n
J 2 /4 0
T u r b o O u tle t P r e s s u re
J 2 /2 4
O il P r e s s u r e
J 2 /3 2
C o o la n t T e m p e r a tu re
J300 P 300
A tm o s p h e ric P re s s u re S e n s o r
A
C
B
+5V
S ig n a l
R e tu rn
P 203 J203
T u rb o O u tle t P r e s s u r e S e n s o r
A
C
B
+5V
S ig n a l
R e tu rn
All fed from Jack 2 (J2) on the ECM
P200 J200
O il P r e s s u r e S e n s o r
+5V
S ig n a l
R e tu rn
A
C
B
P201 J201
C o o la n t T e m p e ra t u r e S e n s o r
C
B
S ig n a l
R e tu rn
J100 P 100
F u e l T e m p e ra tu re S e n s o r
C
B
S ig n a l
R e tu rn
J 2 /3 3
F u e l T e m p e r a tu r e
J 2 /3 5
J 2 /1 8
In le t A ir T e m p e ra tu r e
R e tu rn
J 2 /4 8
J 2 /4 9
C ra n k S p e e d T im in g +
C ra n k S p e e d T im in g -
J 2 /5 8
J 2 /5 9
C a m S p e e d tim in g +
C a m s p e e d t im in g -
J 2 /2 2
J 2 /2 3
C a lib r a tio n P r o b e +
C a lib r a tio n P r o b e -
J105 P105
In le t A ir T e m p e r a t u re S e n s o r
C
B
S ig n a l
R e tu rn
J103 P 103
C ra n k s h a ft P o s itio n S e n s o r
S ig n a l
R e tu rn
2
1
J401 P 401
C a m s h a ft P o s itio n S e n s o r
S ig n a l
R e tu rn
2
1
J402 P402
C a lib r a t io n P r o b e
S ig n a l
R e tu rn
1
2
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
24v dc
J Jack
Possible Bad Connections
Has the same effect as.Resistances in circuit

1 volt
24v dc
Dont forget all connections!
2 volt
Resistors
0.1 volt
Lamp 24v dc
Dont forget all connections!
Lamp
1 volt
19.9v dc
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
de-energised
Fuel
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
coolant
Torque setting on solenoid

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
components
Jack 1 (J1)
Customer interface,
power supply etc
Basic System A3-ECM Interactions

Control
Inputs
Digital speed Adjust
analogue speed
Adjust
PWM speed Adjust
Push
buttons/switches
fault reset,injection
disable,lower/raise
digital speed,
etc,etc
Outputs
PROCESSOR
Cables/
Connectors
Cables/
Connectors
MEMORY
(Engine
Programme)
Power supply
for 5 volt
6.5 volts and
8 volts
Cables/
Connectors
5 volt + 8 volt
Power Supplies
Cables/
Connectors
Electronic
Service
Tool
CAN
110 Volt DC pulse

for Injectors
Digital output
for speed control
ECM power supply,

24 v
PDL
Voltage to operate
diagnostic lamps
and crank terminate
relay
J 1939
Engine Control
J 1939
Diagnostic
Code Reader
M a c h in e W ir in g S c h e m a tic , A ll O p tio n s
T h is W ir in g S u p p lie d B y O E M
2300/2500/2800 Off Engine Wiring Diagram

C r a n k T e r m in a te
(E n g in e R u n n in g
S ig n a l)
N o te s :
O u tp u ts m a y b e u s e d t o
d r iv e la m p s o r re la y s .
ECM
C r a n k T e r m in a te s h o u l d b e
a r e la y u s e d to d is c o n n e c t
th e s ta r te r m o to r in O E M
p a n e l s ta r t c ir c u it.
S h u td o w n
( E C M la t c h e d o u t)
D ia g n o s tic la m p lig h t s
w h e n a c t iv e s y s t e m f a u lt
re g is te r e d
A c t io n A le r t
F o r fu ll d e ta il s o f in p u ts /
o u tp u ts , re fe r to
I n s ta ll a t io n M a n u a l
W a r n in g
P
D ia g n o s tic s
Diagram)
Customer (Different
connection.
J1- 70 Jack Also J3 - 40 Jack - Customer connection
K
L o w O il P re s s u r e
O
H i g h C o o la n t T e m p
N
O v e rs p e e d
O ff - D is a b le d - S t o p
O n - E n a b le d - R u n
I n je c t io n D is a b l e
U
K
N
1 5 0 0 /1 8 0 0 1 8 0 0
rp m S e le c t
Is o c h
D ro o p / D ro o p
Is o c h ro n o u s
A
Y
F a u lt R e s e t
E n a b le
D ig ita l
Speed
C o n tr o l
D ig i ta l S p e e d C o n t r o l D is a b le
Lower Speed
P
O
R a is e S p e e d
To P W M
S p e e d C o n tro l
B
B
W
R
G ro u n d
PW M
+8V
J1 Jack
W
R
B
C h a r g in g
A lte rn a to r
G R D
PO S
E m e rg e n cy
S t o p B u tto n
R
R
O ff
Key O n
S w itc h
Y
Y
C ir c u it
B re a k e r (1 6 A )
S ta rt B u tto n
S ta rte r
M o to r
G
R
B
B a tte ry
24V D C
H C
A c tio n A le r t L a m p O u tp u t
J 1 /2 0
W a r n in g L a m p O u tp u t
J 1 /3 1
D ia g n o s t ic s L a m p O u t p u t
J 1 /2 8
O il P re s s u re L a m p O u tp u t
J 1 /2 9
C o o la n t T e m p e r a t u re L a m p O u tp u t
J 1 /3 0
O v e rs p e e d L a m p O u tp u t
E A
In je c tio n D is a b le
J 1 /6 4
S h u td o w n E m e r g e n c y O v e r r id e
J 1 /5 6
1 5 0 0 /1 8 0 0 r p m S e le c t
J 1 /4 6
D ro o p /Is o c h ro n o u s
J 1 /4 1
F a u lt R e s e t
J 1 /4 9
D ig it a l S p e e d C o n t r o l E n a b le
J 1 /5 9
Low er Speed
J 1 /7
R a is e S p e e d
J 1 /1 8
J 1 /6 7
J 1 /5
J 1 /6 6
D ig it a l G r o u n d
U n s w it c h e d B a t te r y N e g a t iv e
G ro u n d
P W M In p u t
+8V
A n a lo g u e G ro u n d
J 1 /1 7
A n a lo g u e S p e e d In p u t
J 1 /2
+5V
J 1 /6 1
J 1 /6 3
J 1 /6 5
J 1 /4 8
U n s w it c h e d B a t te r y P o s itiv e
J 1 /5 2
J 1 /5 3
J 1 /7 0
S w it c h e d B a tt e r y P o s itiv e
J 1 /5 0
J 1 9 3 9 D a t a L in k +
J 1 /3 4
J 1 9 3 9 D a t a L in k -
J 1 /4 2
J 1 9 3 9 S c re e n
J 1 /8
P e r k in s D a t a L in k +
M a in
B a tt e r y
Feed
(D ir e c t
fro m
s ta r te r /
b a tte r y )
P e r k in s D a t a L in k -
J 1 /5 5
J 1 /6 9
U n s w itc h e d B a t te r y N e g a tiv e
P 1 J1
+
J
J 1 /1 9
J 1 /9
S h u td o w n la m p O u t p u t
J 1 /3
680R
J 1 /1 0
J 1 /4
680R
5 K A n a lo g u e
S p e e d S e ttin g
P o te n tio m e te r o r
In p u t fr o m L o a d
S h a re r /S y n c h r o n is e r
C r a n k T e rm in a t e O u t p u t
J 1 /6 2
O ff
O n
C r it ic a l O v e r r id e
( D is a b l e s O il & W a t e r s h u t d o w n s
when on)
1500
J 1 /1 3
9 P in P e r k in s D a t a
L in k C o n n e c t o r
P
S
S
T
ower
u p p ly to
e r v ic e
ool
Some Typical Connections - ECM

Inputs
CONTROL
ECM
Analogue
Speed Adjust
Outputs
Shutdown
Crank Terminate
Injection Disabled
Diagnostics
Ignition Key Switch
5 volt to
Sensors
ECM Power Supply,

24 v
Communications Adapter
24 v
Power Supply,
24 v
J1939 PDL
23/2800 Series ECM Jack Connections
J2 (Jack 2)
On Engine Mounted Components
J1 (Jack 1)
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.
R a is e S p e e d
J 1 /1 8
J 1 /6 7
J 1 /5
J 1 /6 6
B
B
W
R
G ro u n d
J 1 /4
U n s w itc h e d B a tte ry N e g a tiv e

G ro u n d
P W M In p u t
+8V
J 1 /3
A n a lo g u e G r o u n d
J 1 /1 7
J 1 /2
+5V
J 1 /6 1
J 1 /6 3
J 1 /6 5
J 1 /4 8
U n s w itc h e d B a t te r y P o s it iv e
J 1 /5 2
J 1 /5 3
J 1 /7 0
S w itc h e d B a tte r y P o s itiv e
J 1 /5 0
J 1 9 3 9 D a t a L in k +
J 1 /3 4
J 1 9 3 9 D a t a L in k -
J 1 /4 2
J 1 9 3 9 S c re e n
J 1 /8
P e r k in s D a ta L in k +
J 1 /9
P e r k in s D a ta L in k -
J 1 /5 5
U n s w it c h e d B a t t e r y P o s itiv e
J 1 /6 9
U n s w it c h e d B a t t e r y N e g a t iv e
2300/2800 Series ECM Power Supplies

To PW M
PW M
+8V
680R
5 K A n a lo g u e
P o te n tio m e te r o r
In p u t fro m L o a d
S h a r e r /S y n c h r o n is e r
+ to Diagnostics Lamps
- to Diagnostics Lamps
W
R
680R
C h a r g in g
A lte r n a to r
GRD
PO S
E m e rg e n c y
S to p B u tto n
R
R
O ff
Key O n
S w itc h
Y
Y
C ir c u it
B re a k e r (1 6 A )
G
S ta rt B u tto n
S ta rte r
M o to r
G
N
R
B
B a tte ry
24V DC
P1 J1
+
J
H C G
E A
9 P in P e r k in s D a ta
M a in
B a tte ry
Feed
( D ir e c t
fro m
s ta rte r/
b a tte ry )
P
S
S
T
ower
u p p ly to
e r v ic e
ool
Minimum J1 Connections, to run a

23/2800 Series
Control
ECM
Injection Disabled
Ignition Key Switch
Note
We do suggest that
a connection is made to the

Perkins Electronic Service Tool
(EST) to allow communication
With Perkins Data Link (PDL)
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, Dont 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
Temperature Sensor
Signal
Ground
18
0 Volts

EST Code 110
Temperature can be viewed

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.
Coolant Temperature
Sensor

EST Code 110 (Typical Temperature Sensor graph)
4.8
110-3 Signal shorted to a higher voltage or open circuit (voltage over 4.8)
Volts
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

through the ECM in C/F via:
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.
Manifold Air Inlet

Sensor
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
Higher Temperature lower mass
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.
Fuel Temperature
Sensor
Temperature Sensor Feeds, Harness Voltages
Voltage between 1 and 2
Wiring harness plug connections (check the harness to ECM)

Coolant Temperature Sensor
Intake Manifold Temperature Sensor
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
2
35
18
Fault 1.
Fault 2.
Fault 3.
2300/2800 Series Pressure Sensors

Atmospheric/Crankcase Pressure Sensor
2
5 Volts
14
Signal Voltage
0 Volts
40
Signal Voltage
24
Signal Voltage
Intake Manifold Air Pressure Sensor
Engine Oil Pressure Sensor
ECM J2
23/25/2800 Series Pressure Sensor Operation
6.5 Volts
Pressure Sensor
2
5 Volt
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!)
Pressure can be viewed in PSI and Kpa

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 Sensor
Inlet Manifold Air Pressure Values

2800
1800 rpm
Full load
1/2 Load
1500 rpm
Full Load
1/2 Load
2300
1800 rpm
Full load
1/2 Load
1500 rpm
Full Load
1/2 Load
Kpa Gauge
Inlet Manifold Air
Pressure Sensor
295
126
249
94
263 Half TA Luft
95
Kpa Gauge
205
119
195
71
234 Half TA Luft

71

EST Code 100
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
Engine Oil Pressure

Sensor

EST Code 100 (Typical Pressure Sensor graph)
100-3 Shorted to a higher voltage or open circuit (over 4.8 volts)
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

Kpa, absolute through the ECM
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
Atmospheric
Pressure Sensor
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

C
Voltage between A and B
Voltage between B and C
Voltage between A and C
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
5 Volts
14
Signal Voltage
0 Volts
40
Signal Voltage
24
Signal Voltage
Intake Manifold Air Pressure Sensor
2
3
Fault 1.
Fault 2.
Fault 3.
ECM J2
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
Crankshaft Speed/Position
Sensor fly lead
Crankshaft Sensor Resistance

between 1 and 2
Camshaft Sensor Resistance

between 1 and 2
Run Engine and Measure output

AC Voltage or Frequency from
each Sensor - one at a time
Camshaft Speed/Position
Sensor fly lead
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
Coolant Level sensor
Oil Pressure
Switch
M a c h in e W ir in g S c h e m a t ic , A ll O p t io n s
2800 Wiring Diagram
( E n g in e R u n n in g
S ig n a l)
N o te s :
O u tp u ts m a y b e u s e d to
d r iv e la m p s o r r e la y s .
ECM
K
C r a n k T e r m in a t e s h o u l d b e
a r e l a y u s e d t o d is c o n n e c t
S h u td o w n
( E C M la tc h e d o u t )
D ia g n o s tic la m p lig h ts
w h e n a c tiv e s y s te m fa u lt
r e g is te r e d
A c tio n A le r t
F o r f u ll d e ta ils o f in p u ts /
o u tp u ts , r e fe r to
In s ta lla t io n M a n u a l
W a r n in g
Customer side (Jack 1)
Outputs - may be used to drive lamps or

relays. (0.3 A, 1.0 A and 1.5 A)
Crank terminate should be a relay to

monitor starter motor in the OEM panel
Diagnostic lamp, lights when active fault

code registered, or any of the outputs are
disconnected/open circuit
Inputs - injection disable, RPM select,

digital speed control, raise/lower,
droop/isochronous, etc
For full details of inputs and outputs refer

to the installation manual
(2800,TSL 4262. 2300, TSL 4267)
This drawing for indication only!
D ia g n o s t ic s
K
L o w O il P r e s s u r e
O
H ig h C o o la n t T e m p
N
O v e rsp e e d
O ff - D is a b le d - S to p
I n je c t i o n D i s a b l e
O ff
O n
C r itic a l O v e r r id e
( D is a b le s O il & W a te r s h u td o w n s
w hen on)
1500
K
N
1 5 0 0 /1 8 0 0 1 8 0 0
r p m S e le c t
Is o c h
D ro o p / D ro o p
Is o c h ro n o u s
E n a b le
D ig ita l
Speed
C o n tr o l
D ig ita l S p e e d C o n tr o l D is a b le
Low er S peed
P
O
R a is e S p e e d
To PW M
B
B
W
R
G ro u n d
PW M
+8V
5 K A n a lo g u e
P o t e n t io m e t e r o r
In p u t fro m L o a d
S h a r e r /S y n c h r o n is e r
B
W
R
680R
C h a r g in g
A lte r n a to r
G RD
680R
PO S
E m e rg e n c y
S to p B u tto n
R
R
O ff
Key O n
S w itc h
Y
Y
C ir c u it
B re a k e r (1 6 A )
G
S ta rt B u tto n
S ta rte r
M o to r
G
N
R
B
B a tte ry
24V DC
H C
J 1 /1 0
S h u td o w n la m p O u tp u t
J 1 /1 9
A c tio n A le r t L a m p O u t p u t
J 1 /2 0
W a r n in g L a m p O u t p u t
J 1 /3 1
D ia g n o s tic s L a m p O u t p u t
J 1 /2 8
O il P r e s s u r e L a m p O u t p u t
J 1 /2 9
C o o la n t T e m p e r a tu r e L a m p O u tp u t
J 1 /3 0
J 1 /6 2
J 1 /6 4
J 1 /5 6
1 5 0 0 /1 8 0 0 r p m S e le c t
J 1 /4 6
E A
F a u lt R e s e t
J 1 /4 9
D i g it a l S p e e d C o n t r o l E n a b l e
J 1 /5 9
Low er Speed
J 1 /7
R a is e S p e e d
J 1 /1 8
J 1 /6 7
J 1 /5
J 1 /6 6
J 1 /4
D ig ita l G r o u n d
G ro u n d
P W M In p u t
+8V
J 1 /3
A n a lo g u e G r o u n d
J 1 /1 7
J 1 /2
+5V
J 1 /6 1
J 1 /6 3
J 1 /6 5
J 1 /4 8
U n s w it c h e d B a t t e r y P o s it iv e
J 1 /5 2
J 1 /5 3
J 1 /7 0
S w it c h e d B a t t e r y P o s it iv e
J 1 /5 0
J 1 9 3 9 D a t a L in k +
J 1 /3 4
J 1 9 3 9 D a ta L in k -
J 1 /4 2
J 1 9 3 9 S c re e n
J 1 /8
P e r k in s D a t a L in k +
J 1 /9
P e r k in s D a t a L in k -
J 1 /5 5
U n s w itc h e d B a tte r y P o s itiv e
J 1 /6 9
U n s w itc h e d B a t te r y N e g a t iv e
P 1 J1
+
J
C r a n k T e r m in a te O u t p u t
J 1 /4 1
F a u lt R e s e t
J 1 /1 3
9 P in P e r k in s D a ta
M a in
B a tte r y
Feed
( D ir e c t
fro m
s ta rte r/
b a tte ry )
P
S
S
T
ower
u p p ly to
e r v ic e
ool
Gen-Set Desired Engine Speed/Load Control

The software in the ECM provides the flexibility to
cater for Four types of control.
Digital Control
Pulse Width Modulated
Analogue Control
CAN J1939 Control
Typical Pressure Sensor
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
D ia g n o s tic s
K
L o w O il P r e s s u r e
O
Digital Speed/Load Control
J 1 /3 1
D ia g n o s t ic s L a m p O u t p u t
J 1 /2 8
O il P r e s s u r e L a m p O u t p u t
J 1 /2 9
C o o la n t T e m p e r a tu r e L a m p O u tp u t
Digital speed control (enable/disable)

O v e rs p e e d
J 1 /3 0
Lower speed (pushbutton/relay contact)

J 1 /6 2
In je c t io n D is a b le
J 1 /6 4
J 1 /5 6
1 5 0 0 /1 8 0 0 r p m S e le c t
Raise speed (pushbutton/relay contact)

O ff
O n
when on)
1500
Digital speed control ramp rate, (default 10 rpm/sec)
This can be adjusted via the Electronic

Service Tool
J 1 /4 6
1 5 0 0 /1 8 0 0 1 8 0 0
r p m S e le c t
Is o c h
D ro o p / D ro o p
Is o c h ro n o u s
Speed adjustment ranges +150 150

rpm
F a u lt R e s e t
J 1 /4 1
Y
F a u lt R e s e t
E n a b le
D ig ita l
Speed
C o n tro l
D ig ita l S p e e d C o n tr o l D is a b le
Lower Speed
P
R a is e S p e e d
To PW M
G ro u n d
PW M
+8V
J 1 /4 9
D ig ita l S p e e d C o n tr o l E n a b le
J 1 /5 9
Lower Speed
J 1 /7
R a is e S p e e d
J 1 /1 8
J 1 /6 7
J 1 /5
J 1 /6 6
O
B
B
W
Proprietary Information of Perkins Engines Company
Limited 2006 - All Rights Reserved
J 1 /4
R
U n s w itc h e d B a t te r y N e g a tiv e
G ro u n d
P W M In p u t
+8V
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 OEMs 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 OEMs 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
potentiometer
Provide linear voltage

output (0.5v to 4.5v)
Two series resistors

keep voltage away
from fault region
Fault Region
Voltage o/p
4.5V
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.
M a c h in e W ir in g S c h e m a tic , A ll O p tio n s
Customer Outputs
( E n g in e R u n n in g
S ig n a l)
N o te s :
O u tp u ts m a y b e u s e d to
C r a n k T e r m in a te s h o u ld b e
a r e la y u s e d to d is c o n n e c t
ECM
K
S h u td o w n
( E C M la tc h e d o u t)
re g is te re d
A c tio n A le r t
F o r fu ll d e ta ils o f in p u ts /
In s ta lla tio n M a n u a l
W a rn in g
P
D ia g n o s tic s
K
L o w O il P re s s u re
O
N
O v e rs p e e d
+ Positive - Negative
A
U
J 1 /1 3
C r a n k T e r m in a te O u tp u t
J 1 /1 0
S h u td o w n la m p O u tp u t
J 1 /1 9
A c tio n A le r t L a m p O u tp u t
J 1 /2 0
W a r n in g L a m p O u t p u t
J 1 /3 1
D ia g n o s tic s L a m p O u tp u t
J 1 /2 8
O il P r e s s u r e L a m p O u tp u t
J 1 /2 9
C o o la n t T e m p e r a tu r e L a m p O u t
J 1 /3 0
J 1 /6 2
J 1 /6 4
S h u t d o w n E m e r g e n c y O v e r r id e
O ff
O n
when on)
1500
C r a n k T e r m in a te s h o u ld b e
a re la y u s e d to d is c o n n e c t
S h u td o w n
( E C M la tc h e d o u t)
J 1 /1 0
S h u td o w n la m p O u t p u t
J 1 /1 9
A c t io n A le r t L a m p O u t p u t
Injection Disable/Critical Override

r e g is te r e d
A c tio n A le r t
F o r fu ll d e ta ils o f in p u ts /
I n s t a l l a t i o n M a n u a l
When critical override

W a r n i n g has been enabled in the service tool - the switch
W a r n in g L a m p O u tp u t
J 1 /2 0
when 'open' allows the protection to be over
P
ridden, the switch when closed
ia g n o s tic s
enables the normal Dprotection
- the diagram reads
opposite.
J 1 /the
31
D i a g n o s t i c s L The
a m p O idea
u tp u t
K
was that if you've enabled a feature to over ride protection and the wire
L o w O safe
i l P r e s s u r eresults in you being able to run to destruction.
drops off then the fail
O il P r e s s u r e L a m p O u tp u t
J 1 /2 8
O
C o o l a n t coolant
T e m p e ra tu re
J 1 / 2pressure,
9
Critical Override Not Recommended, Nignores oil
temperature, atmospheric pressure shutdowns when on
O v e rs p e e d
A
U
O ff
O n
when on)
1500
+ 24 Volts
1 5 0 0 /1 8 0 0 1 8 0 0
r p m S e le c t
K
N
Is o c h
D ro o p / D ro o p
Is o c h ro n o u s
F a u lt R e s e t
A
Y
J 1 /3 0
J 1 /6 2
I n je c t io n D is a b le
J 1 /6 4
S h u t d o w n E m e r g e n c y O v e r r id e
J 1 /5 6
1 5 0 0 /1 8 0 0 r p m S e le c t
J 1 /4 6
J 1 /4 1
F a u lt R e s e t
E n a b le
L a m p O u tp u t
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
R
B
J 1 /2
+5V
J 1 /6 1
J 1 /6 3
B
9 Pin (Deutsch)
Diagnostic
Connector
J 1 /6 5
B
R
R
O ff
Key O n
w itc h
Y
Y
A)
G
B u tto n
G
N
R
B
E A
J 1 /4 8
J 1 /5 2
J 1 /5 3
J 1 /7 0
S w it c h e d B a t t e r y P o s it iv e
J 1 /5 0
J 1 9 3 9 D a ta L in k +
Used for Diagnostic Code Reader/

Generic Engine Monitor, (CAN)
Controller Area Network, SAE J1939
Genset Control
J 1 /3 4
J 1 9 3 9 D a t a L in k -
Screen - Unused
J 1 /4 2
J 1 9 3 9 S c re e n
J 1 /8
P e r k in s D a ta L in k +
J 1 /9
P e r k in s D a ta L in k -
J 1 /5 5
J 1 /6 9
U n s w itc h e d B a tte r y N e g a tiv e
P1 J1
B
M a in
B a tte ry
Feed
( D ir e c t
fro m
s ta rte r/
b a tte ry )
Used for Electronic Service Tool

P
S
S
T
ower
u p p ly to
e r v ic e
ool
9 P in P e r k in s D a t a
L in k C o n n e c to r
Electronic Engine Diagnostics
Electronic Service Tool (EST) computer based.
Many functions, reading of temperature, speed, pressures, etc
Genuine network only (including some OEMs 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

Active Diagnostic Codes
Any fault that is currently
Active on the engine.
Logged Diagnostic Codes
Faults that have occurred,
Logged and been repaired.
Logged Event Codes
Problems Events that could
cause permanent damage
Engine coolant temperature
110
CID
FMI
Component/circuit
identifier
Failure mode
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
noticeable performance effects
no
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 49C
Route harness to avoid heat

from the exhaust
manifold/turbocharger
Thermostat
Sensor
Immersion
Heater
Element
Position
Immersion Heater
Element
Connect to: 110/240

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
2800 Series Governor Stability
Make sure Overspeed is

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?

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Perkins 23/25/2800 Series

Diesel Engine Training

Perkins Product Training

The product training information is distributed for

The appropriate service literature, including Service

Wiring Diagrams/Electrical Drawings, wire numbers and

Worldwide Off Road Legislation Today

Off Road Emissions Legislation

Off Road Industrial - Ever Cleaner Engines

Tier 4B: 56kW<560

Tier 4A: 130kW<560

NOx; NOx + HC (g/kWh)

Electronic Engine Benefits

Improved Specific Fuel Consumption (SFC) through precise control of

2306 and 2806 Engine Numbering

H Engine Family, 15.8 litre

FGA 06 - 1234 - U - 5678 - K

A = TAG 1 (Turbo-Air to air charge cooled-Genset)

Engine Ratings - Definitions

Unlimited hours usage, load factor 100%

Unlimited hours usage, load factor 80%

Power available at variable load in the event of a mains power network

2300/2800 Series Engines

2300/2800 - Engine Component Changes

2306/2806 Product Features

Integral inlet manifold

2306/2806 Product Features

2806 -18 litre Product Features

External oil feed

New oil filler

Second oil pressure feed to

Four Valve Mono-Block Cylinder Head

Button and O ring

Inlet valves 1,2,4

With Number 6 Cylinder at TDC compression stroke adjust

Inlet valves 3,5,6

Inlet valves 0.38mm (0.015in)

Exh Valves 0.76mm (0.030in)

A stainless steel sleeve is used in the injector

The sleeve is sealed using three O rings.

The O ring seal fitted on the injector nozzle

Long Overlap Camshaft

Thrust Plate and Seal

Head Gasket/Spacer Plate

Open Summit Cylinder Block

Induction Hardened Liners

Oil soaked filler band

Oil cooling gallery

2806-16 Articulated Piston

Cooling oil reservoir

Tightening con-rod bolts

Big end cap secured by

Oil supply to small end

Piston Cooling Jets

Piston cooling jet

Piston Cooling Jets

Piston cooling jet

Grooved main bearing

180 thrust washers

Block Stiffener Plates

2800 Series 16 litre

Hasse and Wrede Damper

Block Stiffener Plate