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Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved

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Perkins 23/25/2800 Series
Diesel Engine Training
Perkins Product Training
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Domestics
Fire Exits
Breaks
Lunch
Toilets
Smoking
Mobile Phones
Health & Safety
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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.
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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

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Worldwide Off Road Legislation Today
Environmental Protection Agency / European Union
Regional Legislation
No Legislation Requirements
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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.


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Off Road Industrial - Ever Cleaner Engines
0
0 1
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
2 3 4 5 6
Tier 3: 56kW<75
Tier 3: 75kW<130
Tier 3: 130kW<560
Tier 4A: 56kW<130
Tier 4A: 130kW<560
Tier 4B: 56kW<560
NO
x
; NO
x
+ HC (g/kWh)
PM
(g/kWh)
1980s
Particulate Matter
(PM) 0.6g/kWh

Oxides of
Nitrogen
(NOx) 10.00g/kWh
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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
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FGA 06 - 1234 - U - 5678 - K
F Engine Family, 14.6 litre
H Engine Family, 15.8 litre
J Engine Family, 18 litre
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)
Generator Set
Engine
Number of Cylinders
Engine Serial Number
Country of Manufacture
Year of Manufacture 03
Build List
2306 and 2806 Engine Numbering
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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%
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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
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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
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Combined primary and
secondary Eco
Fuel filters
Integral inlet manifold
(18 litre horizontal)
Fuel transfer
pump
Timing
Calibration
Probe access
hole
ADEM 3 ECM
With Perkins
software
Unique wiring
harness
Radial seal
air filter
element
2306/2806 Product Features
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Composite oil pan
Composite
top cover
Oil cooler
Ecoplus full
flow
oil filtration
Single stage
high boost
turbocharger
Torsional
vibration
damper
Air to air
charge
cooler
16 litre
2306/2806 Product Features
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2806 -18 litre Product Features
Twin exhaust
manifolds
External oil feed
to the cylinder
head

Twin
turbochargers

Large output
coolant pump
New oil filler
tube
Aluminium sump
30% larger
capacity oil
cooler

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Rocker Assemblies
Roller Type Rockers
Second oil pressure feed to
cylinder head 18 Litre (external)
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Forged
steel
overhead
camshaft
Four
valves
per
cylinder
Cylinder Head
Four Valve Mono-Block Cylinder Head
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One of three oil
feed drillings
Valve Assemblies
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TDC locator
Turning
tool
Valve/Injector Clearance
Establishing Number 1 TDC
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Valve
screw and locknut
adjuster
Injector adjuster
Injector
trim code
Button and O ring
Valve/Injector Clearance
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Tool CH11149
Machine shoulder
Checking correct
adjustment
Valve/Injector Clearance
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Valve/Injector Clearance
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
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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.

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A failed seal
results in
blow by and a
hot injector
Injector Sleeve
A line
contact seal
is attained
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Injector Sleeve
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Valve lobes Injector lobe
Drive gear
dowel location
Camshaft
Long Overlap Camshaft
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Camshaft
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Camshaft
Thrust Plate and Seal
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Cylinder head gasket
Spacer plate
Shim gasket
Oil feed O ring
Coolant bobbin
Oil seal
Head Gasket/Spacer Plate
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Thermal sleeve
Air gap
Exhaust Manifold
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Cylinder Block
Open Summit Cylinder Block
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Oil soaked filler band
Rubber O rings
(2806)
2306 three lower liner O ring seals are all identical in size
Cylinder Liners
Induction Hardened Liners
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Cylinder Liners
Protrusion
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Oil cooling gallery
Oil cooling spray cutaways
Pistons
2306 Gallery Cooled Articulated Piston
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Cooling oil reservoir
Pistons
2806-16 Articulated Piston
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Tightening con-rod bolts
Piston/Con-Rod Assembly
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Pistons
2806-18 Piston
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Big end cap secured by
four bolts
Oil supply to small end
bearing
Pistons/Con-Rod Assembly
2806-18 Piston
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Piston cooling jet
alignment tool
Part Number GE50004
Piston Cooling Jets
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Piston cooling jet
pipe assembly
Entry to cooling
gallery
Connecting rod
Piston
Piston Cooling Jets
2806-18
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Thrust washer position
Crankshaft
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Crankshaft
2806-18
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Grooved main bearing
fitted to block
180 thrust washers
fitted to block
Crankshaft
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Block Stiffener Plates
2300 Series
2800 Series 16 litre
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2
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
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Pendulum
camshaft gear
Adjustable
idler gear
Idler gear
Fuel transfer
pump
Crankshaft gear
Oil pump gear
position
Compound
gear
assembly
Coolant pump
drive gear
position
Timing Gears
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Locating
dowel
Rotating
balance
weights
Timing Gears
Pendulum Camshaft Gear
Timing case
Alignment
marks
Timing gear
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Timing Gears
Checking Gear Backlash
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Crankshaft Seals
Seal Removal/Fitting
Gear case-split protection ring
Wear sleeve crimp tool
Must be fitted as assembly
Must not be separated
Must be fitted dry
Crankshaft Seals
Oil Seal and Wear Sleeve
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Blue seal (rear) Green seal (front)
Crankshaft Seals
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Induction System
2809-18
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Induction System
Air Filter Type Single medium duty paper element
Max Air Inlet Temp 60C (140F)
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 260C (500F)
at high (ambient conditions)
Turbo Charger 2306 Allied Signal GT 50
2806 Borge Warner S 500
2806-18 twin Borge Warner S310
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Induction System
Radial Seal Filters
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Single stage high boost turbochargers
No oil priming required
Induction System
Turbochargers
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Exhaust gas outlet
Forward turbocharger
Rear turbocharger
Induction System
2806-18 Turbochargers
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A
I
R
C
O
O
L
A
N
T
Induction System
Air Charge Cooling/Radiator
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Air charge cooling / radiator
Boost air
Coolant
Turbo boost air
Coolant
Induction System
2806-18
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Induction System
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Trim code,
Below barcode
Fuel System
EUI Location
Put lever here
to remove Injector
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O ring seals
6 hole
injector nozzle
Sacrificial
compression O ring
Do not re-use seals
Fuel System
Injector Seals
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Transfer pump Primary filter Fuel supply
Fuel return
Venting points
Priming pump
Fuel System
Low Pressure Fuel System
Secondary filter
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Flow =413 litres/h at 1500

Flow =457 litres/h at 1800

Return flow dependant on
engine load Thermostat.
Fuel System
Fuel Cooler/Return
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Fuel System
Ecoplus Fuel Filtration
Fuel System
Fuel Transfer Pump
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Fuel Secondary
Fuel primary
Oil
Fuel System
Ecoplus Fuel Filtration Identification
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From
Tank
To
transfer
pump
From
transfer
pump
Temp sensor
Return to
cooler
Return from
head
Pressure
Relief
Valve
Air vent
Supply to head
Hand
primer
By-pass
valve
Fuel System
Ecoplus Fuel Filtration
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Fuel System
Non-return/PRV
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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)

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Lubrication System
Composite High Capacity Sump
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Lubrication System
Oil Pump
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Sampling
point
O/P switch
Filter by-pass
valve
Cooler by-pass
valve
Lubrication System
Ecoplus Oil Filtration
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Oil cooler
assembly
Re-positioned
oil filler
tube
Re-designed
Oil filter
head
Lubrication System
2806-18
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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
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Composite top and bottom radiator tanks
ELC coolant to be used at all times

Cooling System
Air Charge Cooling/Radiator
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Thermostat
Thermostat seal
Flow to radiator
By-pass
return to
coolant pump
Cooling System
Thermostat Housing
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Coolant
Temp Sensor
Inlet Manifold
Air Pressure
sensor
Fuel Temp Sensor
Inlet Manifold
Air Temp Sensor
Engine Oil and
Atmospheric
Pressure Sensors
Location of Calibration Probe (Plugged)
23/25/2800 Series
Temperature and Pressure Sensors
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Electronic Control
Module
40 Pin Customer
Connection (J3)
110 Volt MEUI Solenoid Feeds
ECM On Engine Connector (J2)
Cam Speed/
Position Sensor
Crank
Speed/Position
Sensor
9 Pin
Diagnostic
Connector
23/2800 Series
Connections and Speed/Position Sensors
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23/25/2800 Series Electrical System

36-1 TOOTH
CRANK
GEAR
36+1 TOOTH
CAM GEAR
Internal Injector Harness
Engine Oil Pressure
Inlet Manifold Sensor
Crank Speed/Timing
Cam Speed/Timing
Atmospheric Pressure Sensor
Calibration Probe
Jack 1 (J1)
Jack 2 (J2)
Fuel Temperature Sensor
Coolant Temperature Sensor
Inlet Manifold Sensor
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23/25/2800 On Engine Wiring Harness
ECM
J2/44 Injector Common Cylinders 1 & 2
Injector
Cyl 1
Injector
Cyl 2
Injector
Cyl 3
Injector
Cyl 4
Injector
Cyl 5
Injector
Cyl 6
J2/45
J2/46
J2/55
J2/54
J2/39
J2/38
J2/37
J2/36
Injector Common Cylinders 3 & 4
Injector Common Cylinders 5 & 6
Injector Cylinder 6
Injector Cylinder 5
Injector Cylinder 4
Injector Cylinder 3
Injector Cylinder 2
Injector Cylinder 1
5
7
6
10
3
11
2
12
1
J300 P300
A
C
+5V
Signal
B Return
A
C
+5V
Signal
B Return
A
C
+5V
Signal
B Return
Atmospheric Pressure Sensor
J2/2
J2/14
J2/3
J2/24
J2/32
J2/33
J2/35
J2/40
Turbo Outlet Pressure Sensor
Oil Pressure Sensor
J2/18
+5VDC Supply
Analogue Return
Fuel Temperature
Inlet Air Temperature
Return
Inlet Air Temperature Sensor
C Signal
B Return
Coolant Temperature Sensor
C Signal
B Return
Fuel Temperature Sensor
C Signal
B Return
Atmospheric Pressure
Turbo Outlet Pressure
Oil Pressure
Coolant Temperature
J2/48
J2/49 Crank Speed Timing -
2 Signal
1 Return
Crankshaft Position Sensor
Crank Speed Timing +
Cam speed timing -
Camshaft Position Sensor
Cam Speed timing + J2/58
J2/59
2 Signal
1 Return
J2/22
J2/23 2
Signal 1
Return
Calibration Probe
Calibration Probe +
Calibration Probe -
P2 J2
P203 J203
P200 J200
P201 J201
J100 P100
J105 P105
J103 P103
J401 P401
J402 P402
J400 P400
All fed from Jack 2 (J2) on the ECM
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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!
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Effects of Bad (Resistance) Connections

24v dc Lamp
Possible Bad Connections
24v dc Lamp Resistors
Has the same effect as.Resistances in circuit
1 volt 2 volt
0.1 volt 1 volt
24v dc
19.9v dc
J Jack P Plug
Dont forget all connections!
Dont forget all connections!
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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
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110v dc injector solenoid
Poppet Valve
Shut when energised
23/25/2800 Series MEUI Injector
+
110v
Supply
Off
-
Flow
Poppet Valve Principals
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Poppet Valve
de-energised
O
Rings
Fuel
chamber
MEUI Injector
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O Rings
Worn MEUI Injector Poppet Valves
Wear on seat, caused by dirty fuel.
Primary Filter 10 microns,
Secondary, 2 microns
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Injector trim code
Injector trim code
Extended life
coolant
Intake
manifold
Fuel chamber
MEUI Injector Location
Torque setting on solenoid
Screws 2.5 Nm (22 lb in)
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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
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Basic System A3-ECM Interactions
Inputs Outputs
Cables/
Connectors
Digital speed Adjust
analogue speed
Adjust
PWM speed Adjust

Push
buttons/switches
fault reset,injection
disable,lower/raise
digital speed,
etc,etc

ECM power supply,
24 v

Control
Voltage to operate
diagnostic lamps
and crank terminate
relay

5 volt + 8 volt
Power Supplies

110 Volt DC pulse
for Injectors

Digital output
for speed control
Cables/
Connectors
Cables/
Connectors
Cables/
Connectors
Electronic
Service
Tool
PDL
PROCESSOR

MEMORY
(Engine
Programme)

Power supply
for 5 volt
6.5 volts and
8 volts
CAN
J 1939
Diagnostic
Code Reader
J 1939
Engine Control
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2300/2500/2800 Off Engine Wiring Diagram

J1- 70 Jack - Customer connection.
Also J3 - 40 Jack - Customer connection

Machine Wiring Schematic, All Options
9 Pin Perkins Data
Link Connector
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active systemfault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30 Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
D E
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input fromLoad
Sharer/Synchroniser
A B G F C
Battery
24V DC
+ -
H J
Unswitched Battery Positive
P1 J1
J1/61 Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70 Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link -
J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link -
J1/55
J1/69
Charging
Alternator
GRD POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64 Shutdown Emergency Override
K
J1/62 Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpmSelect
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7 Raise Speed
O
J1/49 Digital Speed Control Enable
G
J1/59 Lower Speed
P Lower Speed
Enable
Digital
Speed
Control
Disable Digital Speed Control
C
T
PWM
Ground
+8V
J1 Jack
(Different Diagram)
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Some Typical Connections - ECM
Inputs
Outputs
ECM Power Supply,
24 v
CONTROL
E C M
Shutdown
Diagnostics
Analogue
Speed Adjust
Crank Terminate
Injection Disabled
Power Supply,
24 v
+
-
+ -
5 volt to
Sensors
+
-
J1939 PDL
+
-
Ignition Key Switch
Communications Adapter
24 v
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23/2800 Series ECM Jack Connections
J1 (Jack 1)
Customer Side
J2 (Jack 2)
On Engine Mounted Components
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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.

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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.



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2300/2800 Series ECM Power Supplies
Machine Wiring Schematic, All Options
9 Pin Perkins Data
Link Connector
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active system fault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
D E
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
A B G F C
Battery
24V DC
+
-
H J
Unswitched Battery Positive
P1 J1
J1/61 Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70
Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link -
J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link -
J1/55
J1/69
Charging
Alternator
GRD POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64 Shutdown Emergency Override
K
J1/62 Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpm Select
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7 Raise Speed
O
J1/49 Digital Speed Control Enable
G
J1/59 Lower Speed
P Lower Speed
Enable
Digital
Speed
Control
Disable Digital Speed Control
C
T
PWM
Ground
+8V
+ to Diagnostics Lamps
- to Diagnostics Lamps
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Minimum J1 Connections, to run a
23/2800 Series
ECM Power Supply,
24 v
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?
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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.

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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)
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32
33
35
18
ECM
Engine Coolant Temperature Sensor
Fuel Temperature Sensor
Signal Voltage
Signal Voltage
0 Volts
Inlet Air Temperature Sensor
Signal Voltage
2300/2800 Series Temperature Sensors
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18
ECM
Temperature Sensor
R
5 Volts
0 Volts
Signal
Ground
23/2800 Series Temperature Sensor Operation
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Engine Coolant Temperature Sensor
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
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Engine Coolant Temperature Sensor
EST Code 110 (Typical Temperature Sensor graph)
110-4 Signal shorted to a lower voltage (voltage under 0.2)

110-3 Signal shorted to a higher voltage or open circuit (voltage over 4.8)

Temperature
0.2
4.8
Shutdown Temp 361 (3)
Very cold Temp
Action Alert Temp 361 (2)
Warning Temp 361 (1)
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Manifold Air Inlet Temperature Sensor
EST Code 174
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 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)
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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
Perkins Data Link (PDL)
Also enables the calculation of the
fuel limit and engine timing.
Protection, Warning and Action Alert.
Fuel Temperature
Sensor
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Voltage between 1 and 2



Wiring harness plug connections
(check the harness to ECM)
2 1
Fuel Temperature Sensor
Coolant Temperature Sensor
Intake Manifold Temperature Sensor


Temperature Sensor Feeds, Harness Voltages
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32
33
2
35
18
3
2
ECM Jack 2
Engine Coolant Temperature Sensor
Fuel Temperature Sensor
Intake Manifold Temperature Sensor
Fault 1.
Fault 2.
Fault 3.
Break
1
2300/2800 Series Sensors
Different Fault Codes and How they could be Created
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2
3
40
24
14
ECM J2
Engine Oil Pressure Sensor
Intake Manifold Air Pressure Sensor
5 Volts
Signal Voltage
0 Volts
Signal Voltage
Atmospheric/Crankcase Pressure Sensor
Signal Voltage
2300/2800 Series Pressure Sensors
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2
3
ECM J2
Pressure Sensor
R
5 Volt
6.5 Volts
0 Volts
Sensor Fly Lead Main Engine Harness
23/25/2800 Series Pressure Sensor Operation
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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
Perkins Data Link (PDL)
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
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Inlet Manifold Air
Pressure Sensor
Inlet Manifold Air Pressure Values

2800 Kpa Gauge
1800 rpm
Full load 295
1/2 Load 126
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
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Engine Oil Pressure Sensor
EST Code 100
Pressure can be viewed in PSI and
Kpa through the ECM via:
J1939 CAN link
Perkins Data Link (PDL)
Protection,Warning,Action Alert
Protection mapped
Range 106 Kpa to 1135 Kpa
Engine Oil Pressure
Sensor
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Engine Oil Pressure Sensor
EST Code 100 (Typical Pressure Sensor graph)
100-4 Signal shorted to a lower voltage (less than 0.2 volts)
100-3 Shorted to a higher voltage or open circuit (over 4.8 volts)
Pressure
0.2
4.8
Warning Pressure E360-1
Action Alert Oil Pressure E360-3
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Atmospheric (Crankcase) Pressure Sensor
EST Code 274
Pressure can be viewed in PSI and
Kpa, absolute through the ECM
via:
J1939 CAN link.
Perkins Data Link (PDL)
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
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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

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Atmospheric/Crankcase Pressure Sensor (DT06-3S)
Oil Pressure Sensor (DT06-3S)
Intake Manifold Air Pressure Sensor (DT06-3S)



C
A
B
Voltage between A and B
Voltage between B and C
Voltage between A and C
Pressure Sensor Feeds, Harness Voltages
Wiring Harness Plug Connections,
(Checks the harness to ECM)
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2300/2800 Series Sensors
Different Fault Codes and How they could be Created
2
3
40
24
14
3
2
ECM J2
Engine Oil Pressure Sensor
Intake Manifold Air Pressure Sensor
5 Volts
Signal Voltage
0 Volts
Signal Voltage
Atmospheric/Crankcase Pressure Sensor
Signal Voltage
1
Fault 1.
Fault 2.
Fault 3.
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Crankshaft Gear 36 - 1 tooth
Crankshaft Speed/Position Sensor
EST Code 190
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Camshaft Gear 36 + 1 tooth
Camshaft Speed/Position Sensor
EST Code 342 (Speed and timing Sensor 2)
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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
2 1
2 1
Crankshaft Speed/Position
Sensor fly lead
Camshaft Speed/Position
Sensor fly lead
Checking Speed/Position Sensors
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Additional Sensors/Senders
Oil pressure sender
CV18339/3 and adapter 3Y-2888
Coolant temperature sender
CV18338/5 and adapter OE51375
Speed Sensor
CV18338 and Harness
CV18965
Coolant Level switch
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Oil
Pressure
Switch
Temperature
Switch
Coolant Level sensor
Additional Engine Sensors/Senders
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2800 Wiring Diagram
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!
Machine Wiring Schematic, All Options
9 Pin Perkins Data
Link Connector
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active systemfault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
D E
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input fromLoad
Sharer/Synchroniser
A B G F C
Battery
24V DC
+ -
H J
Unswitched Battery Positive
P1 J1
J1/61 Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70 Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link -
J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link -
J1/55
J1/69
Charging
Alternator
GRD POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64 Shutdown Emergency Override
K
J1/62 Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpmSelect
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7 Raise Speed
O
J1/49 Digital Speed Control Enable
G
J1/59 Lower Speed
P Lower Speed
Enable
Digital
Speed
Control
Disable Digital Speed Control
C
T
PWM
Ground
+8V
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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
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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
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Digital Speed/Load Control
Digital speed control (enable/disable)
Lower speed (pushbutton/relay contact)
Raise speed (pushbutton/relay contact)
Digital speed control ramp rate, (default 10 rpm/sec)
This can be adjusted via the Electronic Service Tool
Speed adjustment ranges +150 150 rpm
Machine Wiring Schematic, All Options
9 Pin Perkins Data
Link Connector
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active system fault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
D E
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
A B G F C
Battery
24V DC
+
-
H J
Unswitched Battery Positive
P1 J1
J1/61 Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70
Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link -
J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link -
J1/55
J1/69
Charging
Alternator
GRD POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64 Shutdown Emergency Override
K
J1/62
Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpm Select
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7 Raise Speed
O
J1/49 Digital Speed Control Enable
G
J1/59 Lower Speed
P
Lower Speed
Enable
Digital
Speed
Control
Disable Digital Speed Control
C
T
PWM
Ground
+8V
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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
Typical Pressure Sensor
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)

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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
Typical Pressure Sensor
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)
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2300/2800 Series Analogue Speed
Adjustments
Resistive track
potentiometer
Provide linear voltage
output (0.5v to 4.5v)
Two series resistors
keep voltage away
from fault region
V
o
l
t
a
g
e

o
/
p

4.5V

-10%

+10%

0.5V
Fault Region
Fault Region
1500/1800 RPM
Rated Speed

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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



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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

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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
Warnings, Action Alert and Shutdown
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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.








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Customer Outputs
Machine Wiring Schematic, All Options
9 Pin Perkins Data
Link Connector
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active system fault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
D E
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
A B G F C
Battery
24V DC
+
-
H J
Unswitched Battery Positive
P1 J1
J1/61 Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70
Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link -
J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link -
J1/55
J1/69
Charging
Alternator
GRD POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64 Shutdown Emergency Override
K
J1/62
Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpm Select
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7 Raise Speed
O
J1/49 Digital Speed Control Enable
G
J1/59 Lower Speed
P
Lower Speed
Enable
Digital
Speed
Control
Disable Digital Speed Control
C
T
PWM
Ground
+8V
- Negative
+ Positive
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Injection Disable/Critical Override
When critical override has been enabled in the service tool - the switch
when 'open' allows the protection to be over ridden, the switch when closed
enables the normal protection - the diagram reads the opposite. The idea
was that if you've enabled a feature to over ride protection and the wire
drops off then the fail safe results in you being able to run to destruction.

Critical Override Not Recommended, ignores oil pressure, coolant
temperature, atmospheric pressure shutdowns when on

Machine Wiring Schematic, All Options
9 Pin Perkins Data
Link Connector
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active system fault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
D E
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
A B G F C
Battery
24V DC
+
-
H J
Unswitched Battery Positive
P1 J1
J1/61 Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70
Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link -
J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link -
J1/55
J1/69
Charging
Alternator
GRD POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64 Shutdown Emergency Override
K
J1/62
Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpm Select
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7 Raise Speed
O
J1/49 Digital Speed Control Enable
G
J1/59 Lower Speed
P
Lower Speed
Enable
Digital
Speed
Control
Disable Digital Speed Control
C
T
PWM
Ground
+8V
+ 24 Volts
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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)


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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

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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


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9 Pin (Deutsch) Diagnostic Connector
Machine Wiring Schematic, All Options
9 Pin Perkins Data
Link Connector
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active system fault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
D E
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
A B G F C
Battery
24V DC
+
-
H J
Unswitched Battery Positive
P1 J1
J1/61 Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70
Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link -
J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link -
J1/55
J1/69
Charging
Alternator
GRD POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64 Shutdown Emergency Override
K
J1/62
Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpm Select
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7 Raise Speed
O
J1/49 Digital Speed Control Enable
G
J1/59 Lower Speed
P
Lower Speed
Enable
Digital
Speed
Control
Disable Digital Speed Control
C
T
PWM
Ground
+8V
Screen - Unused
Used for Diagnostic Code Reader/
Generic Engine Monitor, (CAN)
Controller Area Network, SAE J1939
Genset Control
Used for Electronic Service Tool
Perkins Data Link (PDL)
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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
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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

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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

110 3

FMI
CID
Component/circuit
identifier
Failure mode
identifier
Engine coolant temperature

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)
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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




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.


261-13 Engine Timing Calibration Required
23/25/2800 Speed/Timing Calibration
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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
1mm (0.040in)
Timing Calibration Probe Installation
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Crankcase TDC Ref Point
Crankshaft TDC Ref Position
Crankcase Calibration access blank plug
ECM Calibration ref
position
Distance between
TDC position and
ECM Calibration
position approx
100/125 mm
Calibration slot
ECM Timing Calibration Location Position
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2300/2800 Series Immersion Heater
110V/240V immersion heaters and thermostat. Rated at
1500W, thermostat temperature range of 38 to 49C
Immersion
Heater
Element
Position
Route harness to avoid heat
from the exhaust
manifold/turbocharger
Thermostat
Sensor
Connect to: 110/240
Volt Power Supply
Immersion Heater
Element
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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
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2800 Series Governor Stability -
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
Make sure Overspeed is
configured with the EST
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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
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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?
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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?