400SeriesECG

A&I Manual, Publication TPD1812 Production issue 2. Page 1 of 1

Perkins 400D Series Models 403D-15, 403D-15T, 404D-22, 404D-22T, and 404D-22TA

ECG Electronic Governor Application and Installation Guide TPD1657 Publication TPD1812 Production issue 1. Perkins Confidential: GREEN Proprietary information of Perkins Engines Limited, all rights reserved. D16 This information is correct at the time of print Published October 2012.

Contents 400D ECG


1.0 Introduction.................................................................................................................................. 3 1.1 APPLICABLE ENGINES............................................................................................................... 3 1.2 SAFETY.................................................................................................................................... 3

1.2.1 Warning Welding .......................................................................................................... 4 1.2.2 Warning - Electrostatic Paint Spraying ............................................................................ 4 1.2.3 Washing and Painting Processes (Excluding Electrostatic) ............................................ 4 1.2.4 Warning Jump Starting ................................................................................................. 4

2.0 System Principals ........................................................................................................................ 5 2.1 COMPONENT OVERVIEW ............................................................................................................ 5 2.2 ELECTRONIC CONTROL MODULE (ECM)..................................................................................... 5 2.3 PROPORTIONAL ACTUATOR...................................................................................................... 5

2.3.1 All speed .......................................................................................................................... 5 2.3.2 Operation ......................................................................................................................... 5

2.4 ENGINE SPEED SENSOR ............................................................................................................ 6 2.5 MAP SENSOR ........................................................................................................................... 6 2.6 ENGINE ELECTRONIC COMPONENT LOCATION ............................................................................. 7

3.0 Engine System Power and Grounding Considerations............................................................... 8 3.1 GROUND CONNECTION TO ENGINE CYLINDER BLOCK.................................................................. 8 3.2 ECM POWER SUPPLY CONDUCTORS ......................................................................................... 8 3.3 ECM POWER SUPPLY RESISTANCE ........................................................................................... 8 3.4 VOLTAGE SUPPRESSION REQUIREMENT ..................................................................................... 8 3.5 ECM BODY TO CHASSIS MAXIMUM POTENTIAL DIFFERENCE ....................................................... 8

4.0 ECM Application Requirements .................................................................................................. 9 4.1 GOOD WIRING PRACTICES.......................................................................................................... 9 4.2 POWER SUPPLY ........................................................................................................................ 9 4.3 ELECTRICAL SYSTEM ECM DETAILS .......................................................................................... 9 4.4 WIRING SHIELDING .................................................................................................................... 9 4.5 VOLTAGE SUPPLY SYSTEM 12V................................................................................................. 9

5.0 ECG ECM INSTALLATION ....................................................................................................... 10 5.1 ECG ECM MOUNTING ............................................................................................................ 10 5.2 ENGINE ECM VIBRATION......................................................................................................... 10 5.3 MOUNTING RECOMMENDATIONS............................................................................................... 11

6.0 Speed Sensor installation.......................................................................................................... 13 6.1 FITTING TYPE 1 SPEED SENSOR................................................................................................ 13 6.2 FITTING TYPE 2 SPEED SENSOR................................................................................................ 13

7.0 Speed Control............................................................................................................................ 14 7.1 SPEED CONTROL TYPES........................................................................................................... 14

7.1.1 Analogue sensor............................................................................................................ 14 7.1.2 PTO configurations ........................................................................................................ 14 7.1.3 Auto Idle (Machine sensed)........................................................................................... 14 7.1.4 MPTS............................................................................................................................. 15 7.1.5 CAN J1939 .................................................................................................................... 15 7.1.6 Set speed warm up........................................................................................................ 15

8.0 Inputs......................................................................................................................................... 16 8.1 ENGINE PROTECTION INPUT ..................................................................................................... 16

9.0 Outputs ...................................................................................................................................... 17 9.1 REMOTE FAULT LAMP............................................................................................................... 17 9.2 GLOW PLUG RELAY.................................................................................................................. 17 9.3 ALTERNATIVE OUTPUTS ........................................................................................................... 17

10.0 ECM pin usage........................................................................................................................ 18 11.0 Wiring Diagrams/Electrical connections.................................................................................. 19 12.0 Trouble shooting...................................................................................................................... 31

12.1 FAULT CODES........................................................................................................................ 31 13.0 System set up requirements.................................................................................................... 33

13.1 HARDWARE REQUIREMENTS. ................................................................................................. 33 13.2 SOFTWARE REQUIREMENTS................................................................................................... 34 13.3 GETTING STARTED WITH ACT SYSTEM .................................................................................. 34

14.0 ACT Operation and Set-up...................................................................................................... 35 14.1 FILE MENU ............................................................................................................................ 35

14.1.1 Convert ECG Cal to Text ............................................................................................. 35

Contents 400D ECG


14.1.2 Save ECG Cal to File................................................................................................... 35 14.1.3 View Cal File Comments ............................................................................................. 36 14.1.4 Convert Cal File to Text ............................................................................................... 36 14.1.5 View Text File .............................................................................................................. 36 14.1.6 Convert Cal File to Strategy ........................................................................................ 36 14.1.7 Convert a Cal File to a New Strategy (text) ................................................................. 36

14.2 CALIBRATE MENU.................................................................................................................. 36 14.2.1 Change ECG calibration.............................................................................................. 37 14.2.2 Download Cal File to ECG........................................................................................... 37 14.2.3 Compare ECG Call to file ............................................................................................ 37 14.2.4 Change ECG Password............................................................................................... 38 14.3.1 Parameter View ........................................................................................................... 38 14.3.2 Parameter Plot............................................................................................................. 38 14.3.3 Display faults ............................................................................................................... 39 14.3.4 Control strategy ........................................................................................................... 39 14.3.5 Parameter List ............................................................................................................. 39

15.0 CAN Operation ........................................................................................................................ 40 15.1 PARAMETER FORMAT ............................................................................................................ 40

15.2 Lost CAN input signal ..................................................................................................... 40 15.3 Data Frame..................................................................................................................... 41

15.6.1 PGN 61444 ELECTRONIC ENGINE CONTROLLER 1 - EEC1 ................................................. 41 15.6.2 PGN 61443 ELECTRONIC ENGINE CONTROLLER 2 EEC .................................................. 42 15.6.3 PGN 65271 VEHICLE ELECTRICAL POWER 1 - VEP1.......................................................... 42 15.6.4 PGN 0 (R) TORQUE/SPEED CONTROL 1 - TSC1 ................................................................ 42 15.6.5 PGN 61183 ADDR_CLAIM.............................................................................................. 42 15.6.6. PGN 60159 (R) ADDR_CLAIM....................................................................................... 42

16.0 ECG Configuration Settings .................................................................................................... 43 16.1 MAP SENSOR CONFIGURATION AND FUEL LIMITING (WHERE FITTED)....................................... 43 16.2 ECG CONFIGURATION CHARTS .............................................................................................. 46

1.0 Introduction 400ECG


1.0 Introduction This document is intended to provide necessary information for correct installation of the ECG system into 404D-22TA, 404D-22T, 404D-22, 403D-15T & 403D-15 Industrial engines into an off-highway machine. This document is work in progress and will be regularly updated; its purpose is to convey ECG installation information received from various sources. Perkins Engine Company Ltd expects that there will be some additions and modifications to this document as the engine platform matures. The Information herein is the property of Perkins and/or its subsidiaries. Without written permission, any copying, transmission to others, and any use except that for which it is loaned is prohibited. The information contained is the best available at the time of authoring to describe the application and installation requirements of production representative engine and software. During development stages please ensure the Applications Engineering department is consulted before implementing any of the features contained within this document. Early project engines will not have all the features described in this document enabled. Contact the Electronic Applications Team for latest information on software feature release dates.

1.1 Applicable Engines 404D-22TA 404D-22T 404D-22 403D-15T 403D-15 The following engines listed below are not currently available with electronic governing. If this is a requirement please contact your local Perkins representative. 403D-17 403D-11 402D-05

1.2 Safety Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools in order to perform these functions properly. The information in this publication has been based upon current information at the time of publication. Check for the most current information before you start any job. Perkins dealers will have the most current information. Improper operation, maintenance or repair of this product may be dangerous. Improper operation, maintenance or repair of this product may result in injury or death. Do not operate or perform any maintenance or repair on this product until you have read and understood the operation, maintenance and repair information. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work method or an operating technique that is not specifically recommended by Perkins is used, you must be sure that it is safe for you and for other people. You must also be sure that the product will not be damaged and / or that the product will not be made unsafe by the procedures that are used.

1.0 Introduction 400ECG


1.2.1 Warning Welding Welding can cause damage to the on engine electronics. The following precautions should be taken before and during welding:

Turn the engine OFF. Place the ignition keyswitch in the OFF position Disconnect the negative battery cable from the battery. If the machine is fitted with a battery

disconnect switch then open the switch Clamp the ground cable of the welder to the component that will be welded. Place the clamp as close as possible to the weld. Protect any wiring harnesses from welding debris and splatter.

DO NOT use electrical components in order to ground the welder. Do not use the ECM or sensors or any other electronic components in order to ground the welder. 1.2.2 Warning - Electrostatic Paint Spraying The high voltages used in electrostatic paint spraying can cause damage to on engine electronics. The damage can manifest itself through immediate failure of components, or by weakening electronic components causing them to fail at a later date. Electrostatic painting is not recommended. In circumstances where the engine must be painted using electrostatic processes, it is necessary to provide technical details of the applied voltage, estimated current and maximum process exposure time. Electrostatic panting is not permitted without prior consent. As a minimum where the electrostatic process characteristics are acceptable it is necessary to use a common ground for all circuits, including engine sensors, aftertreatment sensors and Glow Plug control units and all other engine electronic circuits. All pins must be connected to a common ground. The engine ECM cannot be painted using electrostatic processes. 1.2.3 Washing and Painting Processes (Excluding Electrostatic) The ECM must not be painted without prior consent. Painting the ECM will reduce heat dissipation capability of the ECM. Perkins recommends that theECM not be painted. If in special circumstances the ECM needs to be painted details of chemicals, covering thickness, color and finish must be provided to ensure compatibility. The flash light and label must remain visable

1.2.4 Warning Jump Starting Jump-starting an engine can cause higher than normal voltages to appear across the battery terminals. Care must be taken that this does not exceed the recommended maximum voltage for the ECM. and engine sensors. The maximum permitted continuous voltage is 16V.

2.0 System Principles 400ECG


2.0 System Principals A microprocessor based controller processes the signals from the speed sensor and MAP sensor (22T and 22TA only). The signal received from the speed sensor is then compared to the desired speed setting. The signal from the MAP sensor provides boost (turbo) pressure monitoring and is used by the ECM to reduce Free acceleration smoke (FAS )during boost. The output of the controller is a pulse width modulated(PWM) signal. The output signal drives a proportional actuator. The actuator converts the signal to an output shaft to move the fuel metering rack and it is proportional to the duty cycle of the pulse width modulated signal.

2.1 Component Overview The main components of the ECG system are listed below and shown in Fig 2.1:

Controller (ECM) (1) Proportional Actuator (2) Speed sensor (3) Manifold Absolute Pressure (MAP) Sensor (4) -optional for turbocharged engines.

Fig 2.1.

2.2 Electronic Control Module (ECM) The ECG ECM is an electronic control device that, via an electronic actuator, governs engine speed and in some cases torque dependant upon information received from input sensors. The ECM should be mounted off the engine following the guidelines in this document. The device has two connections sockets J1 and J2, refer to wiring specifications diagrams/schematics for details, there are no permanent 12volt positive supplies required to the ECM when not in use.

2.3 Proportional Actuator The engine fuel system comprises of lift pump and the electrically controlled governed (ECG) high-pressure inline fuel Injection pump. The ECG ECM controls fuel delivery to the Injectors by controlling a fuel-metering actuator valve. The high-pressure fuel pump provides high-pressure fuel to the Injectors, the quantity determined by a number of ECG ECM inputs, including: Throttle position sensor (desired speed), engine speed and Manifold pressure (Turbo systems). 2.3.1 All speed The engine is governed by an 'All Speed Governor', also known as a Variable Speed Governor. Fig 2.2 illustrates the torque and speed characteristics of this governor. 2.3.2 Operation The All Speed Engine Governor will attempt to hold a constant engine speed for a given throttle position. The governor senses engine speed and meters the fuel supply to the engine such that the engine speed remains constant or varies with the load in a predetermined manner. The all speed governor is also known as 'variable speed' or 'full range engine speed governor'. All speed refers to the fact that the engine governor operates across the full engine speed operating range.



The governor strategy has control parameters classed as governor gains, which determine the engine response and engine stability. These gains are 'tuned' by Perkins to ensure that they are configured for optimum performance under both steady state and transient conditions. As these requirements vary from one application to another it maybe necessary to conduct further tuning to obtain optimal performance for a particular machine. Under default conditions the engine is set to operate with isochronous governing across the engine speed range, during which the engine fuelling is bound by the mechanical torque curve. Note that the engine may not be capable of reaching the mechanical torque curve in some circumstances. For example, if the turbocharger is not providing the required boost pressure, then the fuel will be limited so that the engine does not emit black smoke when Intake Pressure Fuel control (IPFC) is activated.

Fig 2.2

2.4 Engine Speed Sensor The engine is fitted with a speed sensor. It is mounted on the engine flywheel housing to measure the engine crankshaft speed. The crankshaft speed sensor is a inductive pick-up type sensor, which targets the engine flywheel starter ring gear teeth. The ECM is programmable to measure the number of pulses received from the sensor and then determine engine speed. The engine uses the speed sensor on cranking and engine running. operation.** If the crankshaft speed signal is lost during engine running or cranking then the engine will stop/fail to start.

2.5 MAP sensor The engine air system may contain an Intake Manifold Pressure Sensor (MAP) also called boost pressure sensor. The intake manifold pressure sensor measures the air pressure inside the intake manifold, after the turbo. The sensor is used to determine pressure within the manifold and then return a signal relative to the manifold pressure to the ECM as a monitored input. The MAP sensor input is used as a parameter to calculate air fuel ratio limits where a reduction in turbo free acceleration smoke is required. If the MAP sensor return signal exceeds set parameters (such as open or short circuit) a default value is used by the software resulting is less effective control of fuel air ratio and acceleration smoke. A



fault code will be returned if MAP sensor return signal is exceeding set parameters. If the ECG system is to be fitted retrospectively then procedures need to be followed to remove the mechanical boost control system (22T and 22TA only).

2.6 Engine Electronic Component location

Crankshaft speed sensor Flywheel housing Manifold pressure sensor Inlet manifold housing Electronic Actuator- Rear of injector pump ECM- Customer location (see mounting locations)

3.0 Engine System Power and Grounding considerations 400ECG


3.0 Engine System Power and Grounding Considerations

3.1 Ground Connection to Engine Cylinder Block. An engine cylinder block ground point is required on all machines in addition to the engine starter motor ground, which also requires a separate ground connection. It is important to avoid system ground potential differences. The maximum potential difference between ECM switch to ground references and the cylinder block is 1V. The ECM ground connections must be separate from the cylinder block and must be routed directly to the battery.

3.2 ECM Power Supply Conductors To prevent voltage drop, avoid sharing and feeding the engine ECM supply circuit with or via other machine component circuits.

The minimum recommended conductor cross-section for each ECM pin is from (1.5mm) AWG16 to (1.0mm) AWG18.

The maximum recommended end of life resistance for the total circuit, including positive and negative conductors is 50mOhms.

When calculating the resistance of a circuit it is important to consider the resistance of the cable and connection points of the entire circuit.

3.3 ECM Power Supply Resistance The recommended machine end of life total ECM power supply circuit resistance is 50mOhms. Perkins advise a target resistance of 40mOhms.

3.4 Voltage Suppression Requirement The ECM must be protected against high voltage spikes, also known as load dump. The factory fitted Alternators are fitted with load dump protection as standard to protect the engine ECM. Load dump protection protects against high transient voltages sometimes seen when switching inductive components in the system circuit. The factory fitted alternators protect for voltages higher than 25V-30V depending on the alternator selected. If an alternator is not used or a non-standard alternator is selected the engine electrical system must be designed to provide load dump protection for the engine ECM. The maximum permissible transient voltage measured at the ECM is 30Vdc.

3.5 ECM Body to Chassis Maximum Potential Difference The measured potential difference between the ECM body and ECM battery ground should be kept to a minimum. Ideally there should be no difference.

The maximum permissible difference is 1V.

4.0 ECM Application Requirements 400ECG


4.0 ECM Application Requirements

4.1 Good wiring practices Good wiring practices include: routing signals separated by type, keeping power & signals separated, and twisting signal/return pairs as well as power & return pairs. Engine speed signal, MAP sensor and variable speed input wires must be grounded as close to terminal J1-04 as possible. Wiring shielding is to be used as indicated on the wiring diagrams.

4.2 Power Supply The ECG ECM requires no permanent electrical power feed when not in use. A key switched fused 12v supply is to be used to power up the ECG system The ECG power source is to be direct from the battery (via fuse/switch) to minimize volt drop losses to the system when engine cranking. System fuse rating is slow blow 10amp (@ 12v)

4.3 Electrical System ECM Details The ECG ECM has working range of 9 to 30 Vdc reverse polarity protected, however, the actuator restricts the working voltage to 9-15Vdc.

4.4 Wiring shielding Wiring shielding is to be used as per wiring diagrams and are to be grounded near to ECM plug J1 pin 04.

4.5 Voltage Supply System 12V Minimum ECM Voltage 9V, Maximum ECM Voltage 15V Reverse polarity protected.

5.0 ECG ECM Installation 400ECG


5.0 ECG ECM INSTALLATION

5.1 ECG ECM Mounting To ensure best endurance for both mechanical vibrations and humidity the ECG ECM must be mounted in accordance with requirements listed below and precautions illustrated in Fig 5.1. Details of the ECM dimensions are shown in Fig 5.2. Fig 5.1

The ECM must be mounted off Engine The ECG ECM must be located so that :

The operating temperature is maintained between - 40 and + 185 F ( - 40 to +85 C).

The vibration does not exceed 6 Gs from 40 to 2000 Hz. Vibration isolation should be used if required.

It is protect the from direct exposure to impact or abrasion. There is adequate space around the unit for servicing and wiring.

The ECG unit and associated wires must not be installed near high-voltage or high-current vices. If this is not possible then the unit and all connected and associated wires must be appropriately shielded..

The cable from the ECM must be secured using a suitable P clip. The ECM must be orientated to ensure no fluid is allowed to build on the surface of the ECM

or allowed to track into the

5.2 Engine ECM Vibration The ECM is designed for chassis or frame mounting. The vibration levels produced by the engine exceed the limits of the ECM design and therefore it is essential that the ECM should be mounted away from the engine and any associated components with the same vibration profile. Under no circumstances should the ECM be mounted to the engine.



5.3 Mounting Recommendations Hard Mounting Hard mounting the ECM is the preferred method, providing the vibration environment is suitable. If there is an existing isolated structure in the application such as a cab or operator platform then that may provide the lowest vibration environment for the ECM. Where possible mounting brackets should be avoided, direct mounting to stiff structures is recommended. If this is not possible the bracket should be of a stiff design. Avoid mounting on large flat panels such as fuel tanks or engine covers, particularly in the centre, to avoid any panel resonances. Isolation Mounting If a suitable hard mounting location cannot be found, then isolation (iso) mounts may be considered to reduce the vibration input to the ECM. The development of a suitable isolation system may be more difficult however. The iso mounts must be optimized to the mass and mounting orientation of the ECM, and the application inputs. Measurement Method A Power Spectrum Density (PSD) measurement is required for each installation. Vibration data should be measured on the ECM in positions defined by the test procedure. A vibration profile for the application should be created based on a combination of several typical operating conditions. Data should be gathered for each of the three orthogonal axis of the ECM, vertical, axial (fore-aft), and transverse (side-side). The levels from several typical operating conditions should be measured. These may then be combined into a composite typical vibration profile for that application. The exact operating conditions should be reflect typical machine use, and be repeatable. Please contact your Application Engineer for details of the measurement points.



Fig 5.2 Controller dimensions

6.0 Speed Sensor Installation 400ECG


6.0 Speed Sensor installation Speed sensor installation is critical in order to prevent permanent damage to sensor and erratic performance or non start situations. There are currently two types of speed sensors that may be fitted. 1. External thread 3/8-24 UNF with protruding inductive tip and thread adaptor ring. 2. External thread M18x1.5 with flush inductive tip Both types of sensor have a threaded locking ring to secure the sensor in correct placement. Sensor 1 requires the flywheel tooth to be in line with threaded hole where the sensor is to be fitted, as light contact between the flywheel tooth tip and the sensor inductive tip will be used as an initial reference point for clearance gap setting.

6.1 Fitting type 1 speed sensor. Fit thread adaptor into flywheel housing and tighten. Carefully screw speed sensor into adaptor until light contact with top of flywheel tooth is obtained. Unscrew sensor back (away from tooth) by of a turn and lock into position using locking ring. When all system connections are complete and if fitment of sensor is successful then ECM lamp should illuminate on cranking, if this is not the case the sensor should be screwed in a further 1/16th of a turn and test again. Repeat as necessary, but do not screw sensor in more than 3/16th of a turn in total. Use the locking ring to secure sensor in place after every adjustment. If using feeler gauges a gap of 0.25mm should be set.

6.2 Fitting type 2 speed sensor. Carefully screw speed sensor into adaptor until light contact with top of flywheel tooth is obtained. Unscrew sensor back (away from tooth) by 1/2 of a turn and lock into position using locking ring to tightening torque of 37NM +/- 4NM. When all system connections are complete and If fitment of sensor is successful then ECM lamp should illuminate on cranking. If using feeler gauges a gap of 0.75mm should be set.

7.0 Speed Control 400ECG


7.0 Speed Control It is necessary to select a device that converts the desired speed of the engine operator or controller to an electronic signal recognized by the ECM. The speed demand type must be carefully considered and be appropriate for the application. The options must be selected at the time of order so that the ECM will be configured correctly for the control device selected. Consult your Applications Engineer for more information.

7.1 Speed control types There are five types of speed demand input: 1. Analogue sensor* 2. PTO (cruise control / set speed) or Auto idle. 3. Multi-position throttle switches (MPTS) / Rotary switch 4. CAN J1939 interface (TSC1 1939) 5. Machine sensed auto idle 7.1.1 Analogue sensor Analogue sensors should use non-contact Hall effect technology within a set voltage range. A voltage above or below this range will indicate an open or short circuit. A robust potentiometer contact sensor (throttle sensor) designed for use in vehicles may also be considered. A resistance value of 3-5k is recommended. * Under no circumstances should ordinary carbon track or wire wound potentiometers be used as they will not be reliable. If an idle verification switch (IVS) is configured in conjunction with sensor, and analogue sensor and IVS inputs do not agree, the engine speed will operate at 10% of actual position of analogue sensor input. Analogue input parameters may be preset for volume production. To calibrate the analogue sensor refer to System Set up section 13 of this guide and Mode settings on page 47. Once in mode 255 run the throttle sensor through its full range of travel, the system file will automatically learn and store the range values in its memory. 7.1.2 PTO configurations PTO configurations can be set to switched inputs to allow:

Engage PTO function (disengage variable speed inputs) Ramp up speed (speed raise button) Ramp down speed (speed lower button)

The rate of ramp-up / ramp down speed can be configured, as can requested rate of speed change. Setting must be specified at time of order. As a safety feature, when the engine is initially turned on, the mode is assumed to be PTO OFF regardless of the PTO switch setting. Users have to cycle the PTO switch OFF and then back ON to enable PTO input. An auxiliary output for indicator lamp may be used to indicate PTO on mode. This lamp could also be used for fault indication and would differentiate between PTO on and fault read by signal type output (flashing/permanently on) 7.1.3 Auto Idle (Machine sensed) Note: In this instance the IVS pin is used as a machine switched system to indicate there is a no load status and cannot be used in conjunction with analogue speed idle conformation. Auto-idle mode is a configurable switchable function and is possible as a set speed (Normally idle) input. When selected, the engine speed will reduce to a set (idle) speed when the idle verification (machine function) is active after a set ramp down time, for instance, when machine has not been

7.0 Speed Control 400ECG


used for specified time. Once load has been detected the pre-determined speed will be resumed. This function is not an option if MPTS (Multi position Throttle switch) speed control is a selected. 7.1.4 MPTS MPTS (Multi position throttle switch) or rotary switch configuration can be set to switchable inputs to allow up to four pre-determined engine speeds (these speeds must be specified at time of order), The rate of engine speed change (ramp up/down rate) can be also configured between selected speeds (rate of speed change may be adversely affected by engine load). Refer to wiring diagrams to ensure correct switch configuration. In order to incorporate these switched inputs, determine the speed mode that is required for the application. 7.1.5 CAN J1939 CAN J1939 interface is also possible using TSC1. CAN communications require the use of appropriately rated cable and each end of the communication bus to be terminated with two 120 Ohms from CANH to CANL at their ends. 7.1.6 Set speed warm up Within the configurable software is a set speed warm up this feature will hold the engine at a pre-determined speed for a pre-determined time after start up.

8.0 Inputs 400ECG


8.0 Inputs Several supply inputs may be required (power and switched), power on supply from the power switch must take priority to pin J1-09 for volts positive. Ground supply for ECM (J1-04) must be direct from the battery. All other inputs to the ECM requiring a ground or positive battery supply must be suitably connected to the supplying cable (after fuse and power on switch for positive) or close to the ECM pin for the supplying ground.

8.1 Engine protection input Controlled shutdown for engine protection can be configured by a switchable ground input to J2-09 in the event of engine system failure such as below threshold oil pressure or engine temperature overheating. These input switches can be set in parallel so if any one of them exceeds parameters the engine will shut down. Engine protection shutdown will cause the governor actuator pin to move to a position of zero fueling, it will not switch off the ECM.

9.0 Outputs 400ECG


9.0 Outputs Other than the ECM output to the electronic governor, various auxiliary output configurations are possible, however the maximum current draw on each auxiliary output is 200ma.

9.1 Remote fault lamp A remote fault lamp can be configured using an auxiliary output, this output can be varied to display different features such as Flashing = fault , On= PTO selected or Auto Idle selected.

9.2 Glow plug relay The ECM can also be configured to control a glow plug relay (controlled via output from pin J2-04 max current draw 200ma), switching the relay for a pre-determined time dependant upon on/off signal input to pin J2-09, however to prevent damage to the glow plug system, please contact your Perkins application engineer for further information.

9.3 Alternative outputs Details in 9.1 and 9.2 are typical uses for outputs from ECM, however they are not limited to these functions and can be tailored to individual customer needs.

10.0 ECM pin usage 400ECG


10.0 ECM pin usage The pin usage shown in Table 10.1 shows how ECM pins are allocated to particular inputs and outputs. Due to the number of possible applications present there are in some cases a pin use Clash. Whilst it is necessary in the case of Ground and battery fed 12v positive to have several connections near to the ECM pin, it would not be possible to have signal wires (input or output) used for multipurpose connections. Therefore careful consideration must be given to application essentials and desirables to ensure there is no pin clash when choosing possible options. Due to the versatility of the ECM a good range of input and output combinations are available, consult your Perkins Application Engineer to enable best application for you machine

11.0 Wiring Diagrams/Electrical connectors 400ECG


11.0 Wiring Diagrams/Electrical connections Wiring diagrams given on the following pages are examples only.



Table 11.1



J1-03SP

EED

SE

NSO

R IN

PUT (N

EG)

J1-04BA

TTER

Y N

EGA

TIVE S

UP

PLY

400 series ECG

ECM

J1 & J2 C

onnector

J1-09K

EY S

WITC

H (TER

MIN

AL 15)

J1-01C

OM

MS

TOO

L CO

NN

ECTIO

N

OFF

ON

STA

RT

IGN

ITION

KEY

SW

ITCH

STA

RT

4

3 1

2

Speed sensor

J1-02C

OM

MS

TOO

L CO

NN

EC

TION

J1-11C

OM

MS

TOO

L CO

NN

ECTIO

NJ1-12

CO

MM

S TO

OL C

ON

NEC

TION

J1-10SP

EED S

ENSO

R IN

PU

T (PO

S)

12v BA

TTER

Y (1)

-+

MA

PJ2-01

MA

P S

IGN

AL

J2-10M

AP

SEN

SOR

SU

PPLY

SEN

SOR

R

ETU

RN

Actuator

J1-08G

OV

ERN

OR

OU

TPUT N

EG

J1-05G

OV

ERN

OR

OU

TPUT P

OS

J2-04AU

X 2 MAX

200mA D

RA

WC

OLD

STAR

T CO

NTR

OL

J1-06C

AN LO

W J1939

J1-07C

AN H

IGH

J1939

Can 1939.

Optional speed

input

GLO

W P

LUG

RE

LAY

GR

OU

ND

AU

X

OU

TPU

TO

ptional remote fault

code lamp

J2-07SP

EED

CO

NTR

OL 1 O

PTION

AL

J2-08SPE

ED

CO

NTR

OL 2 O

PTIO

NA

L

SP

EED

4

SP

EED

3

SP

EED

2

SPE

ED

1 - NO

CO

NN

ECTIO

N

J2-12SPE

ED

DEM

AN

D SIG

NA

L

J2-115V

RE

F

J2-02SIG

NA

L RETU

RN

VAR

IABLE

SPEED

C

ON

TRO

L (optional)

SWITC

HED

S

PEE

D

CO

NTR

OL

(optional)

J2-03G

RO

UN

D SW

ITCH

ED

OU

TPU

T

10 AM

P S

LOW

BLO

W

60ma quick

blow

J2-09TEM

PER

ATUR

E S

WITC

H

1.5mm

(16AW

G)

1.0mm

(18AW

G)

1.5mm

(16AWG

)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AWG

)

1.0mm

(18AW

G)

1.5mm (16AWG)1.0m

m (18A

WG

)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.5mm (16AWG)

To Glow

Plugs

AU

X 2 MAX

200mA

DR

AW

1.0mm

(18AW

G) or 1.5m

m (16AW

G)

J2-05ID

LE V

ERI FIC

ATION

IDLE VE

RIF IC

ATIO

N SW

ITCH

1.0mm

(18AW

G)

Fig 11.1 N

B: A

ll options shown cant be used sim

ultaneously



J1-03SPE

ED SE

NSO

R IN

PUT (N

EG)

J1-04BA

TTER

Y N

EGA

TIVE SU

PPLY

400 series ECG

EC

M J1 &

J2 Connector

J1-09KE

Y SWITC

H (TER

MIN

AL 15)

J1-01C

OM

MS

TOO

L CO

NN

EC

TION

OFF

ON

STA

RT

IGN

ITION

KEY

SWITC

H

STA

RT

4

3 1

2

Speed sensor

J1-02C

OM

MS

TOO

L CO

NN

EC

TION

J1-11C

OM

MS

TOO

L CO

NN

EC

TION

J1-12C

OM

MS

TOO

L CO

NN

EC

TION

J1-10SPEED

SEN

SOR

INP

UT (P

OS)

12v BATTER

Y (1)

-+

MA

PJ2-01

MA

P SIGN

AL

J2-10M

AP SEN

SOR

SU

PPLY

SENSO

R

RETU

RN

ACTU

ATO

RJ1-08

GO

VE

RN

OR

OU

TPUT N

EG

J1-05G

OVER

NO

R O

UTPU

T POS

J2-04AU

X 2 MAX 200m

A DR

AWC

OLD

STAR

T CO

NTR

OL

J1-06C

AN LO

W J1939

J1-07C

AN

HIG

H J1939

GLO

W P

LUG

RELAY

GR

OU

ND

AU

X

OU

TPU

TO


code lamp

J2-12SPE

ED D

EMAN

D SIG

NA

L

J2-115V R

EF

J2-02S

IGN

AL R

ETU

RN

VARIA

BLE SPE

ED

CO

NTR

OL

(optional)

J2-03G

RO

UN

D S

WITC

HE

D O

UTPU

T

10 AMP

SLO

W BLO

W

60ma quick

blow

J2-09TEM

PER

ATU

RE

SW

ITCH

1.5mm

(16AWG

)

1.0mm

(18AW

G)

1.5mm

(16AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)1.0m

m (18AW

G)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

To Glow

Plugs

AUX 2 M

AX 200mA D

RAW

1.0mm

(18AWG

) or 1.5mm

(16AWG

)

J2-06

PTO R

AMP U

P1.0m

m (18AW

G)

1.0mm (18AWG)

SYSTEM U

SING

AN

ALO

GU

E D

ESIRED

ENG

INE SPEED

IN

PUT &

PTO IN

PUT

PTO E

NG

AGE

/DISEN

GA

GE

ANALO

GU

E CO

NTR

OL

J2-07P

TO R

AMP D

OW

N

J2-08PTO

RAM

P U

P

PTO

RAM

P DO

WN

1.0mm

(18AWG

)

PTO E

NG

AGE

/DISE

NG

AGE

ANALO

GU

E CO

NTR

OL

1.0mm

(18AWG

)

Fig 11.2



J1-03SPE

ED SE

NSO

R IN

PUT (N

EG)

J1-04BA

TTER

Y N

EGA

TIVE SU

PPLY

400 series ECG

ECM

J1 & J2 C

onnector

J1-09KE

Y SWITC

H (TER

MIN

AL 15)

J1-01C

OM

MS

TOO

L CO

NN

ECTIO

N

OFF

ON

STA

RT

IGN

ITION

KEY

SWITC

H

STA

RT

4

3 1

2

Speed sensor

J1-02C

OM

MS

TOO

L CO

NN

EC

TION

J1-11C

OM

MS

TOO

L CO

NN

ECTIO

NJ1-12

CO

MM

S TO

OL C

ON

NEC

TION

J1-10SPEED

SEN

SOR

INP

UT (P

OS)

12v BATTER

Y (1)

-+

MA

PJ2-01

MA

P SIGN

AL

J2-10M

AP SEN

SOR

SU

PPLY

SENSO

R

RETU

RN

ACTU

ATO

RJ1-08

GO

VERN

OR

OU

TPUT N

EG

J1-05G

OVER

NO

R O

UTPU

T POS

J2-04AU

X 2 MAX 200m

A DR

AWC

OLD

STAR

T CO

NTR

OL

J1-06C

AN LO

W J1939

J1-07C

AN H

IGH

J1939

Can 1939.

Optional speed

input

GLO

W P

LUG

RELAY

GR

OU

ND

AU

X O

UTP

UT

Optional rem

ote fault code lam

p

J2-07SPEE

D C

ON

TRO

L 1 OPTIO

NA

L

J2-08SPE

ED C

ON

TRO

L 2 OP

TION

AL

SPEED

4

SPEED

3

SPEED

2

SPEED

1 - NO

CO

NN

ECTIO

N

SWITC

HED

SPEE

D

CO

NTR

OL

(optional)

J2-03G

RO

UN

D SW

ITCH

ED O

UTPU

T

10 AMP

SLO

W BLO

W

60ma quick

blow

J2-09TEM

PER

ATUR

E SWITC

H

1.5mm

(16AWG

)

1.0mm

(18AW

G)

1.5mm

(16AWG

)

1.0mm

(18AW

G)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

1.0mm

(18AWG

)1.0m

m (18AW

G)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

To Glow

Plugs

AUX 2 M

AX 200mA D

RAW

1.0mm

(18AWG

) or 1.5mm

(16AWG

)

SYSTEM U

SING

SWITC

HA

BLE

FOU

R SPEED

INPU

T

Fig 11.3



J1-03SP

EED

SEN

SOR

INPU

T (NEG

)

J1-04B

ATTE

RY

NEG

ATIV

E SU

PPLY

J1-09K

EY S

WITC

H (TE

RM

INA

L 15)

J1-01C

OM

MS

TOO

L CO

NN

EC

TION

OFF

ON

STA

RT

IGN

ITION

KEY

SWITC

H

STA

RT

4

3 1

2

Speed sensor

J1-02C

OM

MS

TOO

L CO

NN

EC

TION

J1-11C

OM

MS

TOO

L CO

NN

EC

TION

J1-12C

OM

MS

TOO

L CO

NN

EC

TION

J1-10SP

EED

SEN

SOR

INP

UT (P

OS)

12v BATTER

Y (1)

-+

MAP

J2-01M

AP

SIG

NA

L

J2-10M

AP

SEN

SOR

SU

PPLY

SEN

SOR

R

ETU

RN

ACTU

ATO

RJ1-08

GO

VER

NO

R O

UTPU

T NE

G

J1-05G

OV

ERN

OR

OU

TPUT PO

S

J2-04A

UX 2 M

AX

200mA

DR

AWC

OLD

STA

RT C

ON

TRO

L

J1-06C

AN LO

W J1939

J1-07C

AN H

IGH

J1939

GLO

W P

LUG

RE

LAY

GR

OU

ND

AU

X

OU

TPU

TO


code lamp

J2-08SP

EED C

ON

TRO

L 2 OP

TION

SPEE

D 2

SPE

ED

1 - NO

CO

NN

ECTIO

N

SWITC

HED

S

PEE

D

CO

NTR

OL

(optional)

J2-03G

RO

UN

D SW

ITCH

ED

OU

TPUT

10 AM

P

SLO

W BLO

W

60ma quick

blow

J2-09TE

MPE

RATU

RE

SWITC

H

1.5mm

(16AWG

)

1.0mm

(18AWG

)

1.5mm

(16AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AWG

)

1.5mm (16AWG)

To Glow

Plugs

AU

X 2 M

AX

200mA D

RA

W

1.0mm

(18AWG

) or 1.5mm

(16AWG

)

400 series ECG

ECM

J1 & J2 C

onnectorSYSTEM

USIN

G SW

ITCH

AB

LE TW

O SPEED

INPU

T AN

D M

AC

HIN

E SW

ITCH

ED A

UTO

IDLE

J2-05ID

LE VE

RI FIC

ATIO

N ID

LE VE

RIF IC

ATION

SW

ITCH

J2-07A

UTO

IDLE

SW

ITCH

AUTO

IDLE S

WITC

H

MA

CH

INE

SEN

SED

Fig 11.4



J1-03SPE

ED SE

NSO

R IN

PUT (N

EG)

J1-04BATTE

RY

NEG

ATIVE

SUPPLY

400 series ECG

ECM

J1 & J2 C

onnector

J1-09K

EY

SW

ITCH

(TER

MIN

AL 15)

J1-01C

OM

MS

TOO

L CO

NN

ECTIO

N

OFF

ON

STAR

T

IGN

ITION

KE

Y

SW

ITCH

STA

RT

4

3 1

2

Speed sensor

J1-02C

OM

MS

TOO

L CO

NN

ECTIO

NJ1-11

CO

MM

S TO

OL C

ON

NEC

TION

J1-12C

OM

MS

TOO

L CO

NN

ECTIO

N

J1-10SP

EED S

ENSO

R IN

PU

T (PO

S)

12v BA

TTER

Y (1)

-+

MA

PJ2-01

MA

P SIG

NAL

J2-10M

AP S

ENSO

R SU

PPLY

SENSO

R

RE

TUR

N

AC

TUA

TOR

J1-08G

OV

ERN

OR

OU

TPUT N

EG

J1-05G

OV

ERN

OR

OU

TPUT PO

S

J2-04A

UX

2 MA

X 200m

A D

RA

WC

OLD

STAR

T CO

NTR

OL

J1-06C

AN

LOW

J1939

J1-07C

AN H

IGH

J1939

GLO

W P

LUG

RE

LAY

GR

OU

ND

AU

X

OU

TPU

TO


code lamp

J2-12SPEED

DEM

AND

SIGN

AL

J2-115V R

EF

J2-02SIG

NAL R

ETUR

N

VARIABLE

SPEED

C

ON

TRO

L (optional)

J2-03G

RO

UN

D SW

ITCH

ED O

UTPU

T

10 AMP

SLO

W BLO

W

60ma quick

blow

J2-09TEM

PER

ATUR

E SW

ITCH

1.5mm

(16AW

G)

1.0mm

(18AWG

)

1.5mm

(16AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AW

G)

1.0mm

(18AWG

)1.0m

m (18AW

G)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

To Glow

Plugs

AU

X 2 M

AX

200mA D

RA

W

1.0mm

(18AWG

) or 1.5mm

(16AW

G)

J2-05ID

LE VERIFIC

ATION

J2-05I D

LE VERIFIC

AT ION

IDLE VER

IFICATI O

N SW

ITCH

J2-07AU

TO ID

LE SWITC

H

MAC

HIN

E SEN

SED

Analogue speed control and

idle verification

Fig 11.5



J1-03SP

EE

D S

EN

SO

R IN

PUT (N

EG

)

J1-04BA

TTER

Y N

EGA

TIVE SU

PP

LY

400 series ECG

ECM

J1 & J2 C

onnector

J1-09K

EY

SW

ITCH

(TER

MIN

AL 15)

J1-01C

OM

MS

TOO

L CO

NN

ECTIO

N

OFF

ON

STA

RT

IGN

ITION

KEY

SWITC

H

STA

RT

4

3 1

2

Speed sensor

J1-02C

OM

MS

TOO

L CO

NN

EC

TION

J1-11C

OM

MS

TOO

L CO

NN

ECTIO

NJ1-12

CO

MM

S TO

OL C

ON

NEC

TION

J1-10SP

EED

SE

NS

OR

INP

UT (P

OS

)

12v BATTER

Y (1)

-+

MAP

J2-01M

AP S

IGN

AL

J2-10M

AP S

ENS

OR

SU

PPLY

SEN

SO

R

RE

TUR

N

AC

TUA

TOR

J1-08G

OV

ERN

OR

OU

TPU

T NE

G

J1-05G

OV

ERN

OR

OU

TPU

T POS

J2-04AU

X 2 M

AX 200m

A D

RAW

CO

LD S

TART C

ON

TRO

L

J1-06C

AN LO

W J1939

J1-07C

AN H

IGH

J1939

GLO

W P

LUG

RELAY

GR

OU

ND

AU

X

OU

TPU

TO


code lamp

J2-12S

PEED

DE

MA

ND

SIG

NA

L

J2-115V

RE

F

J2-02S

IGN

AL RETU

RN

VAR

IAB

LE SP

EE

D

CO

NTR

OL

(optional)

J2-03G

RO

UN

D SW

ITCH

ED

OU

TPUT

10 AMP

SLO

W BLO

W

60ma quick

blow

J2-09TEM

PE

RATU

RE

SWITC

H

1.5mm

(16AWG

)

1.0mm

(18AWG

)

1.5mm

(16AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)1.0m

m (18AW

G)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.0mm

(18AWG

)

1.5mm (16AWG)

To Glow

Plugs

AU

X 2 MA

X 200m

A DR

AW

1.0mm

(18AWG

) or 1.5mm

(16AWG

)

J2-05ID

LE VE

RI FIC

ATION

J2- 05ID

LE V

ER

IFICA

T ION

IDLE

VER

IFICA

TI ON

SW

ITCH

J2-07A

UTO

IDLE

SW

ITCH

MAC

HIN

E S

EN

SED

Analogue speed control and

idle verification

Fig 11.6



02 0103040506070809101112 02 0103040506070809101112

J1J2

+

3+

2

4

6

5

(2) Actuator

(3) Speed sensor

(4) Battery

(6) Speed selection switch

(5) ECM

power on sw

itch

(1) J1 & J2 connector

+

1

02 0103040506070809101112

J1

02 0103040506070809101112

J2 1

+

2

45

+

3+

Grey

Black

(2) Actuator

(3) Speed sensor

(4) Battery

(5) EC

M pow

er on switch


6

(6) Variable speed control

Signal

5V Ref

Return

Variable speed wiring

diagram(N

on 22T or TA)

Two speed w

iring diagram

(Non 22T or TA

)Fig 11.7



02 0103040506070809101112

J1

02 0103040506070809101112

J2 1

02 0103040506070809101112

J1

02 0103040506070809101112

J2 1

+

2

45

+

3+

+

2

45

+

3+

Glow

plug relay

Temperature sw

itch

Over tem

perature switch

Oil pressure sw

itch

Rem

ote lamp

Single set speed with glow

plug relay output and tem

perature switch

Single set speed with engine

protection and remote lam

p

(2) Actuator

(3) Speed sensor

(4) Battery

(6) Glow

plug realy

(5) EC

M pow

er on switch


(7) Engine tem

perature switch

6

7

67

(2) Actuator

(3) Speed sensor

(4) Battery

(6) Rem

ote lamp

(5) ECM

power on sw

itch


(7) Engine protection sw

itches

Fig 11.8



02 0103040506070809101112

J1

02 0103040506070809101112

J2 1

02 0103040506070809101112

J1

02 0103040506070809101112

J2 1

+

2

45

+

3+

+

2

45

+

3+

Glow

plug relay

Temperature sw

itch

Over tem

perature switch

Oil pressure sw

itch

Rem

ote lamp

Single set speed with glow

plug relay output and tem

perature switch

Single set speed with engine

protection and remote lam

p

(2) Actuator

(3) Speed sensor

(4) Battery

(6) Glow

plug realy

(5) EC

M pow

er on switch


(7) Engine tem

perature switch

6

7

67

(2) Actuator

(3) Speed sensor

(4) Battery

(6) Rem

ote lamp

(5) ECM

power on sw

itch


(7) Engine protection sw

itches

Fig 11.9



02 0103040506070809101112

J1

02 0103040506070809101112

J2 1

02 0103040506070809101112

J1

0506070809101112

J2 1

+ 2

4

5

+

3+

+

2

45

+

3+

6

7

(2) Governor

(3) Speed sensor

(4) Battery

(6) J1939 TSC

1 CA

N

Speed Control

(5) EC

M pow

er on switch


(7) MA

P sensor

(Applicable on 404D-

22T &TA only)

Variable speed using C

AN

J1939 TSC1 input.

SW

ITCH

ED

SPEED

C

ON

TROL

(optional)

SPEE

D 4

SPEE

D 3

SPEE

D 2

SWITC

HED SPE

ED

CO

NTR

OL (optional)

02 010304

60ma quick

blow

6

Switchable Four speed w

iring diagram

Speed 1

(No connection)

(2) Governor

(3) Speed sensor

(4) Battery

(6) Sw

itchable speed input

(5) EC

M pow

er on switch


Fig 11.10

12.0 Trouble Shooting 400ECG


12.0 Trouble shooting All checks are to be carried out by a competent engineer. Battery voltage supply to the ECM must be checked at power on and during cranking to

ensure ECM supply voltage does not fall below parameters. Check wiring connections are clean and securely fitted. Check actuator pin is free moving and clear of contamination. If no signal is received from Speed sensor, and system had previously been operational,

check sensor pick-up tip for contamination. Failure to adequately fuse protect the MAP 5v reference wire may result in

permanent ECM damage, never replace the fuse until fault cause has been rectified.

12.1 Fault codes The ECM is capable of identifying certain fault conditions and alerting the user to them. A flashing LED indicates the fault condition. The flashing LED is located on the casing of the ECM, however an LED may be mounted remotely using an ECM output. The fault code list is shown in table 12. before checking fault codes in table 12 please note the following:

No flash will be displayed if the ECM has a power supply failure. When power is first applied to the ECM, the LED will flash once for one second to indicate the

power is on and LED is working. If there are multiple faults, the LED will flash them in sequence. Count all the flash codes to

determine fault codes. If there are no faults recorded, the LED will flash once and from then on will indicate the

detection of engine speed signal (engine cranking and running). The controller will attempt to shutdown when some faults are encountered and may not permit

starting with faults 1,5 and 8 on Table 12 below.

12.0 Trouble Shooting 400ECG


Table 12.

13.0 System set up requirements 400ECG


13.0 System set up requirements System configuration and PID set-up require the use of hardware (computer, interface module and communications lead) and a software programme known as ACT. Higher volume orders may be supplied with pre-configured ECM,s once specifications have been agreed and application testing has been conducted. The information on the following pages is to be used in conjunction with the Mode configuration and calibration charts shown on page 47 onwards. Failure to use correct settings may result in engine damage.

13.1 Hardware Requirements. ACT interface tool and break out leads PC compatible computer with serial communications port or suitable serial port to USB adapter

(USB1.1 or 2.0 RS232 Converter) and Windows 95/98/ME/2000/XP/Vista operating system (Act has not been completely tested and verified under Vista and windows 7)

64 of available RAM memory and hard disk with at least 4MB of free disk space. SVGA capable video card and screen/monitor capable of 256 colours and 800 x 600 display.

Fig 13.1

13.0 System set up requirements 400ECG


13.2 Software Requirements The ACT software resides on the PC and communicates through the interface module to the ECM via a breakout lead on J1 grey plug. ACT software is available for download to your PC, contact your Perkins dealer/distributor for further information. A pop up display box will require you to input which computer port is to be used to communicate with ACT.

Important: Ensure power to your ECM is switched off before connecting the ACT and computer interfaces

13.3 Getting Started with ACT System Once software has been loaded onto the computer and all connections are complete as per diagram 13.31, switch on the power supply to ECM and click on software icon on the computer, no information can be uploaded, viewed or downloaded until power supply to ECM is complete.

Connection Established Connection Not Established

14.0 ACT Operation and set-up 400ECG


14.0 ACT Operation and Set-up Note; in the following sections, calibration file is referred to as Cal File and the ECM as ECG Unless already pre-programmed to a required specification, the ECG will require a set up depending upon inputs/outputs being used and general configuration of system. The current set up can be viewed clicking File Save ECG file to TextEnter file save destination, this displays file current file in the ECG, details of these instructions can be found later in this section. It is recommended that the virgin file is saved on you computer and can be referred back to if required. The system prompts the operator to save data under a file name and add comments to that file, this is particularly useful when fine tuning the system to note engine behavior. Caution: Take care when changing ECG parameters to ensure settings to not exceed engines capability i.e; max speed.

14.1 File menu The File Menu allows you to perform operations related to viewing, saving and converting files.

Note: Cal files saved are in binary form and not directly readable as text Text files are saved in text form and not readable by ECG. The following commands are available under the File Menu.

Save ECG Cal to File View Cal File Comments View Text File Convert ECG Cal to Text Convert Cal File to Text Convert Cal File to Strategy

14.1.1 Convert ECG Cal to Text File Convert ECG Cal to TextEnter your text file nameOK This allows you to save the current ECG file in text form, but is not recognizable in its current format as a file that can be sent back to the ECG 14.1.2 Save ECG Cal to File File Save ECG Cal to FileEnter your file nameClick save. This command allows you to save ECG calibration data to a designated file and add Cal File comments (see view CAL file comments). This file format is only recognizable by ECG.



The ACT uploads the calibration set from ECG and saves it to a computer ACT file. This operation is usually done after the controller has been calibrated for satisfactory engine performance but can also be done at any othertime. The data is saved in a binary file format 14.1.3 View Cal File Comments This command allows you to display the comments that are attached to a calibration file. Users add comments when saving a calibration file. The comments help in tracking specific engine, application, and environment data for which the calibration file was created. 14.1.4 Convert Cal File to Text FileConvert Cal File to TextSelect fileopen This allows a saved binary Cal File to be saved as a separate text file and be viewed in text format and if required printed. A text format file cannot be downloaded to ECG. 14.1.5 View Text File File View Text FileChoose file to viewOpen This command allows you to view a saved text file, displaying calibration features including PIDs 14.1.6 Convert Cal File to Strategy File Convert Cal File to StrategyEnter file to send to ECG This command is used to convert old ACT files for use with controllers that have a different control strategy version. ACT will Parse through all of the calibration parameters in the old ACT file and search for the same calibration parameters in the new ACT file and assign values from the old calibration. 14.1.7 Convert a Cal File to a New Strategy (text) FileConvert Cal File to StrategyEnter name ACT will read all of the calibration values from the controller create and save a text file with the parameter names, values, and units, then display the file using the default text viewer.

14.2 Calibrate Menu The Calibrate Menu allows you to perform operations related to ECG calibration. The following commands are available:

Change ECG Calibration* Download Cal File to ECG* Compare ECG Cal to File Cal Change ECG Password* Calibration Wizard*

(*) These commands can be password protected to prevent unauthorized calibration changes. See Change ECG Password for more information.



The data sheets 14.2A shows a list of configuration options and a description, explanation and mode settings that may require entering when changing calibration settings, at any point when setting theses configurations on the ACT system there is a help hot-key F1. Within the Spreadsheet there is a reference to Mode, this is required for the ECG to recognize types of input required ie; CAN speed input, switched speed input and number of switched speeds, if warm up time is required and Units for how long to stay in warm up configuration etc. 14.2.1 Change ECG calibration All adjustments are stored immediately in non-volatile memory in the ECG unit. The ECG controller will retain the changes even if power is lost or the ACT is disconnected. CalibrateChange ECG CalibrationView filter(drop down menu)Highlight parameter to view/changeChange parameter value if reqdEnter. The new value is written to the controller and then read back, with the result placed in the ECG Value field. 14.2.2 Download Cal File to ECG The Download Cal File to ECG command allows you to download the entire calibration set from a file to the ECG permanent memory. This is convenient one-step method for:

Reverting back to a known good calibration set after experimenting with new calibration settings Programming multiple ECG units for a particular application

The downloaded file may have been previously configured and calibrated for satisfactory engine performance with another ECG unit. 14.2.3 Compare ECG Call to file This command lets you check the differences in calibration sets between a saved file and the ECG unit. The feature is useful, for example, to ensure that the saved file matches the calibration in the ECG unit. CalibrateCompare ECG file to CalSelect fileOK Once all parameters have been processed, a message box will list the compare results. If the parameters in the file match the controller, the following message box appears:

If there were mismatches, the following message will appear showing file differences.



You can save to file to enable differences to be compared at a later date. 14.2.4 Change ECG Password This command allows you to add or change a password to protect certaincalibration features. The option is useful, for example, to prevent unauthorizedchanges to a known good calibration set in the ECG unit. Once a password is added or changed, the following calibration features become password protected:

Change ECG Calibration Download Cal File to ECG Change ECG Password ECG Calibration Wizard

At the start of any future sessions, if a password has been set, ACT will always prompt you to enter the password to gain access to these features. You only need to enter the password once during any session to gain access to all the password protected features. CalibrateEnter password. 14.3.1 Parameter View This command allows you to view certain operating variables in real time. To view parameter values in Real Time: MonitorParameter View. Real time values are shown. The screen automatically starts reading values from the controller and displaying the values. To stop the updating, click on Stop, the button name will then change to Start. Clicking it again will start updating again. The parameters viewed can be changed/added to by selecting from the drop down configure menu below the Start/stop option 14.3.2 Parameter Plot The Parameter Plot command lets you view engine performance on screen in the form of a real-time graph. This feature allows you to perturb the system and observe the response to fine tune engine performance. MonitorParameter Plot.



The application will launch and start the parameter plot view. The plot can be stopped and started as required and saved to file in text form. Parameters shown on the graph can be chosen from the configuration list and graph settings altered to required resolutions. PID setting are shown at the base of the graph and can be altered (even with engine running), the PID`s will not change until new number has been input and the return/enter button has been clicked on your computer Plot parameters and inputs can be altered/set from the configure menu in the plot screen. Monitorparameter plotconfigurechoose parameterSave. A maximum of two plots can be displayed simultaneously. If power supply to ECM is switched off, screen plot will be lost(unless previously saved under save to file). 14.3.3 Display faults This command allows you to display present faults in real-time. This means if new faults occur while you are monitoring, the screen will automatically update to display the current faults. The display will also show historical fault codes that have been previously logged but do not currently exist. Historical fault codes are helpful when tracking down intermittent faults. Monitordisplay faults. Both current and historical faults are displayed in the separate box displays, these faults can be cleared by clicking on clear historical faults or clear current faults. Individual faults displayed within the same box cannot be cleared separately. 14.3.4 Control strategy This command allows you to check the version of the control strategy in use. This information may be needed for strategy identification purposes and for future updates. 14.3.5 Parameter List The Parameter List screen allows the user to adjust which parameters are displayed on the Parameter View display. MonitorParameter listselect desired parameter and position

Type in a file name that reflects the purpose of the saved configuration and click Save. The view configuration dialog will now display the selected file name in the title bar. Clicking Open will prompt the user for a file name of a previously saved View Configuration. Select the desired file and click Open. The View Configuration will be updated with the saved parameters. The ACT application will always recall the default set of plot configuration parameters at application startup, and does not recall the last used view setup file. So the view configuration will always start with the default view. Several parameter view screens can be open with different configurations by changing the configuration on the parameter list screen (F9 or Open), then opening a new Parameter View.

15.0 CAN Operation 400ECG


15.0 CAN Operation CAN connections: CANL (J1-6) and CANH (J1-7) lines are used for CAN communications. CAN networks must be terminated with a 120 +1% differential resistance at each end of the network. It is necessary to terminate the network to prevent interference caused by signal reflections. Depending on length, many CAN networks will not operate at all without the proper termination. Generally it is recommended not to build the termination into a node since CAN is intended to be a plug-n-play type network with RIUP (remove and insert under power). However, no specific restrictions are placed on the inclusion of termination resistors in a node. Termination resistors must be installed only at the physical ends of the network. Terminating other midpoint units can overload the network and stop all communications. As a rule, no matter how many units are on a network, there should never be more than two terminations installed. Termination is a simple 120 watt, 1% metal film resistor placed between CAN high and CAN low terminals (differential termination) on or near the two end units. Data pair impedance 120 10% AT 1 MHZ Cable capacitance 12 pF/ft at 1 kHz (nominal) Capacitive unbalance 1200 pF/1000 ft at 1 kHz Propagation delay 1.36 ns/ft (maximum) DC resistance 6.9 W / 1000 ft @ 20 C (maximum

Data pair 19 strands, 1.0 mm corresponds to 18 AWG,individually tinned, 3 twists/foot

Power pair 19 strands, 1.5 mm corresponds to ~16 AWG,individually tinned, 3 twists/foot

Drain / shield wire 19 strands, tinned copper shielding braid or shielding braid and foil

Cable type Twisted pair cable, 2x2 lines

Bend radius 20 x diameter during installation or 7 x diameter fixed position 0.13 dB/100 ft @ 125 kHz (maximum) 0.25 dB/100 ft @ 500 kHz (maximum) Signal attenuation 0.40 dB/100 ft @ 1000 kHz (maximum)

15.1 Parameter Format The ECG uses a Little-Endian format when handling multiple-byte parameters (i.e. a position demand of 50% is FF0F, not 0FFF). All parameters use this format unless otherwise specified. 15.2 Lost CAN input signal When the EXTERNAL_ANALOG_MODE is configured to receive demanded speed from CAN, if new demanded speed updates are not received within the configured CAN_LOST_DELAY a CAN_DEFAULT_SPEED is taken. There is no fault indication. Desired speed will default to CAN_Default_speed..



15.3 Data Frame The ECG uses CAN 2B with 29-bit identifiers. The Data Frame is the most common message type. It comprises the following major parts:

The Arbitration Field which determines the priority of the message when two or more nodes are contending for the bus. The Arbitration Field contains: a 29-bit Identifier (which also contains two recessive bits: SRR and IDE) and the RTR bit.

The Data Field which contains zero to eight bytes of data. The CRC Field which contains a 15-bit checksum calculated on most parts of the message.

This checksum is used for error detection. An Acknowledgement Slot. Any CAN controller that has been able to correctly receive the

message sends an Acknowledgement bit at the end of each message. The transmitter checks for the presence of the Acknowledge bit and retransmits the message if no acknowledge was detected.

15.4 Device Identifier The Device Identifier is a not configurable parameter. The default value contains manufacturer code Perkins Governor identifier: 153. All the others fields are set to 0. Moreover CAN Source Address cannot be changed by Address Claim Procedure. The default value is set to 0x00. It means that only one ECG controller can exist on a single CAN link. If it is required (another device uses the same source address) ECG CAN Source Address parameter can be modified by ACT Tool. 15.5 Transmitted and Received CAN Messages The following information is sent over the CAN:

Engine speed Vehicle Battery Status Engine Shutdown Request

The following information is sent over the CAN upon request:

Address Claim The ECG CAN Controller receives the following information over CAN: Speed Setpoint Address Claim

15.6 Supported Frames

15.6.1 PGN 61444 Electronic Engine Controller 1 - EEC1 Engine related parameters. Transmission Repetition Rate: 20 ms Data Length: 8 Default Priority: 3 Parameter Group Number: 61444 (0xF004) Start Position Length Parameter Name SPN

4-5 2 bytes Engine Speed 190 7.1 4 bits Engine Starter Mode 1675

Engine Starter Mode SPN assumes starter motor sense at SW2 input.



15.6.2 PGN 61443 Electronic Engine Controller 2 EEC Identifies electronic engine control related parameters. Transmission Repetition Rate: 50 ms Data Length: 8 Default Priority: 3 Parameter Group Number: 61443 (0xF003) Start Position Length Parameter Name SPN

1.1 2 bits Accelerator Pedal 1 Low idle Switch 558 2 1 byte Accelerator Pedal Position 1 91

15.6.3 PGN 65271 Vehicle Electrical Power 1 - VEP1 Transmission Repetition Rate: 1 s Data Length: 8 Default Priority: 6 Parameter Group Number: 65271 (0xFEF7)

Start Position Length Parameter Name SPN 7-8 2 bytes Keyswitch Battery Potential 158

15.6.4 PGN 0 (R) Torque/Speed Control 1 - TSC1 Data Length: 8 Default Priority: 3 Parameter Group Number: 0 (0x0) Start Position Len

400SeriesECG

Documents

d ecg ai manual

d series models

engine system power

engine speed sensor

ecm power supply conductors

ecm power supply resistance

perkins confidential

electronic control module