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40

KENR6933

Troubleshooting Section

7.

If the repairs have not eliminated the faults

proceed to “Throttle Signal for the Speed Demand

Input”.

Signal for the Speed Demand Input

1.

Use the electronic service tool and observe the

signal for the speed demand input.

2.

If the signal is erratic, refer to Troubleshooting,

“Speed Demand Circuit (Analog) - Test” or refer to

Troubleshooting, “Speed Demand Circuit (Digital)

- Test”.

3.

If the fault has not been eliminated, proceed to

“Air Intake and Exhaust System”.

Air Intake and Exhaust System

1.

Check the air

fi

lter restriction indicator, if equipped.

2.

Ensure that the air

fi

lter is clean and serviceable.

3.

Check the air intake and the exhaust system for

the following defects:

•

Blockages

•

Restrictions

•

Damage to the air intake and exhaust lines and

hoses

4.

Make all necessary repairs to the engine.

5.

Ensure that the repairs have eliminated the fault.

6.

If the fault has not been eliminated, proceed to

“Valve Lash”.

Valve Lash

1.

Check the valve lash and reset the valve lash, if

necessary. Refer to Systems Operation, Testing

and Adjusting, “Engine Valve Lash - Inspect and

Adjust”.

2.

If the repair does not eliminate the fault proceed

to “Turbocharger”.

Turbocharger

Note:

The turbocharger that is installed on this

engine is a nonserviceable item. If any mechanical

fault exists, except for the wastegate actuator, then

the turbocharger must be replaced. The wastegate

actuator can be replaced.

1.

Ensure that the mounting bolts for the turbocharger

are tight.

2.

Check that the oil drain for the turbocharger is not

blocked or restricted.

3.

Check that the compressor housing for the

turbocharger is free of dirt, debris and damage.

4.

Check that the turbine housing for the turbocharger

is free of dirt, debris and damage.

5.

Check that the turbine blades rotate freely in the

turbocharger.

6.

Ensure that the wastegate on the turbocharger is

adjusted correctly. Refer to Testing and Adjusting,

“Turbocharger - Inspect”. If the wastegate actuator

is faulty, replace the wastegate actuator. Refer

to Disassembly and Assembly, “Turbocharger -

Disassemble” and Disassembly and Assembly,

“Turbocharger - Assemble”.

7.

If necessary, replace the turbocharger. Refer

to Disassembly and Assembly, “Turbocharger

- Remove” and Disassembly and Assembly,

“Turbocharger - Install”.

8.

Check that the repairs have eliminated the faults.

9.

If the repairs have not eliminated the fault proceed

to “Fuel Supply”.

Fuel Supply

1.

Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

2.

Ensure that the fuel supply valve is in the full

OPEN position.

3.

If the temperature is below 0 °C (32 °F), check

for solidi

fi

ed fuel (wax).

4.

Visually inspect the fuel supply lines for

restrictions.

5.

Check that the low pressure fuel lines are tight

and secured properly.

6.

Remove the fuel

fi

lters. Inspect the fuel

fi

lters for

contamination. Install new fuel

fi

lters. Refer to the

Operation and Maintenance Manual, “Fuel System

Filter- Replace and Fuel System Primary Filter

(Water Separator) Element - Replace”. Determine

the cause of the contamination.

7.

Check the diesel fuel for contamination. Refer to

Systems Operation, Testing and Adjusting, “Fuel

Quality - Test”.

8.

Check for air in the low pressure fuel system. Refer

to Systems Operation, Testing and Adjusting, “Air

in Fuel - Test”.

Summary of Contents for 1106C Genset

Page 1: ...May 2007 Troubleshooting 1106C Genset PK Engine KENR6933 00 ...

Page 2: ...ning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Perkins cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive If a tool procedure work method or o...

Page 3: ...Consumption 57 Excessive Valve Lash 59 Excessive White Smoke 60 Intake Air Temperature Is Too High 61 Intermittent Engine Shutdown 62 Intermittent Low Power or Power Cutout 63 Low Engine Oil Pressure 64 Low Power Poor or No Response to Throttle 65 Mechanical Noise Knock in Engine 68 Noise Coming from Cylinder 68 Troubleshooting with a Diagnostic Code Diagnostic Code Cross Reference 70 No Diagnosti...

Page 4: ...5 Volt Sensor Supply Circuit Test 104 CAN Data Link Circuit Test 111 Data Link Circuit Test 114 ECM Memory Test 120 Electrical Connectors Inspect 121 Engine Pressure Sensor Open or Short Circuit Test 125 Engine Speed Timing Sensor Circuit Test 132 Engine Temperature Sensor Open or Short Circuit Test 140 Fuel Rail Pump Solenoid Test 145 Ignition Keyswitch Circuit and Battery Supply Circuit Test 150...

Page 5: ...tor 2 Solenoid for the Fuel Rail Pump 3 Wastegate Regulator if equipped 4 Secondary Speed Timing Sensor 5 Fuel Rail Pump 6 Primary Speed Timing Sensor 7 Intake Manifold Pressure Sensor 8 Fuel Rail Pressure Sensor 9 Engine Oil Pressure Sensor 10 Intake Manifold Temperature Sensor 11 Coolant Temperature Sensor 12 Diagnostic Connector if equipped 13 Electronic Control Module ECM ...

Page 6: ...sensor for the intake manifold pressure Speed timing sensors Speed demand input At start up the ECM determines the top center position of the number 1 cylinder from the secondary speed timing sensor in the fuel rail pump The ECM decides when fuel injection should occur relative to the top center position The ECM optimizes engine performance by control of each of the electronic unit injectors so th...

Page 7: ...swords contain alphabetic characters only an electronic service tool may change System Configuration Parameters System Configuration Parameters affect the power rating or the emissions Refer to Troubleshooting Programming Parameters and Troubleshooting Factory Passwords i02517212 Glossary Active Diagnostic Code An active diagnostic code alerts the operator or the service technician that an electro...

Page 8: ...engine The ECM provides power to the electronics The ECM monitors data that is input from the sensors of the engine The ECM acts as a governor in order to control the speed and the power of the engine Electronic Service Tool The electronic service tool allows a computer PC to communicate with the ECM Engine Monitoring Engine Monitoring is the part of the electronic engine control that monitors the...

Page 9: ...used for purposes of emission control When the ECM senses a higher intake manifold air pressure more air into the cylinder the FRC increases the FRC Limit more fuel into the cylinder Full Load Setting FLS The FLS is the parameter that represents the fuel system adjustment This adjustment is made at the factory in order to fine tune the fuel system The correct value for this parameter is stamped on...

Page 10: ...s The electronic system requires correct passwords in order to change some parameters Factory Passwords Refer to Troubleshooting Factory Passwords for more information Personality Module See Flash File Power Cycled Power cycled happens when power to the ECM is cycled ON OFF and ON Power cycled refers to the action of cycling the keyswitch from any position to the OFF position and to the START RUN ...

Page 11: ...l This adjustment is made in order to correct the timing error between the camshaft and the engine speed timing sensors or between the crankshaft and the engine speed timing sensors Top Center Position The top center position refers to the crankshaft position when the engine piston position is at the highest point of travel The engine must be turned in the normal direction of rotation in order to ...

Page 12: ...unction for ECM replacement Data logging Graphs real time Table 3 lists the service tools that are required in order to use the Electronic Service Tool Table 3 Service Tools for the Use of the Electronic Service Tool Part Number Description 1 Single Use Program License 1 Data Subscription for All Engines 27610251 Communication Adapter Electronic Service Tool to ECM interface 27610164 Adapter Cable...

Page 13: ...ch is turned to ON the lamp will come on for 2 seconds The lamp will then go off unless there is an active warning Flashing The lamp will be flashing when a derate is active or when a derate is present because of an active diagnostic code An example of an active diagnostic code is System Voltage High On The lamp will be on when the shutdown level in the engine protection strategy has been reached ...

Page 14: ...at one or more of the warning values for the engine protection strategy has been exceeded However the value has not been exceeded to a level that will cause a derate or a shutdown The engine is operating normally However there is one or more of the monitored engine parameters that are outside of the range that is acceptable Flashing Flashing Derate Warning and Derate If both the warning lamp and s...

Page 15: ...ubleshooting Guide No Diagnostic Code Detected As an example an active diagnostic code of 21 is indicated by the Warning lamp coming on for 500 ms then off for 300 ms then on for 500 ms then off for 2000 ms then on for 500 ms and then off g01194272 Illustration 4 After all of the active diagnostic codes have been displayed the Shutdown lamp will go off for 2 seconds The Shutdown lamp will flash tw...

Page 16: ...CM Note When a new ECM is not available you may need to remove an ECM from an engine that is not in service The ECM must have the same serial number suffix Ensure that the replacement ECM and the flash file match the suspect ECM Be sure to record the parameters from the replacement ECM Use the Copy Configuration ECM Replacement function in the Electronic Service Tool NOTICE If the flash file and e...

Page 17: ...rates a diagnostic code This indicates the specific problem with the circuitry Diagnostic codes can have two different states Active Logged Active Code An active diagnostic code indicates that an active problem has been detected by the control system Active codes require immediate attention Always service active codes prior to servicing logged codes Logged Code Every generated code is stored in th...

Page 18: ...perature Sensor 3 Intake Manifold Pressure Sensor 4 Fuel Rail Pressure Sensor 5 Electronic Control Module ECM 6 Oil Pressure Sensor 7 Primary Speed Timing Sensor 8 Secondary Speed Timing Sensor 9 Solenoid for the Fuel Rail Pump Note If equipped the wastegate regulator is installed on the right side of the engine ...

Page 19: ...KENR6933 19 Troubleshooting Section g01178875 Illustration 6 ...

Page 20: ...sor 3 Pin Connector P228 Fuel Rail Pressure Sensor 3 Pin Connector P200 Intake Manifold Pressure Sensor 3 Pin Connector P103 Intake Manifold Temperature Sensor 2 Pin Connector P100 Coolant Temperature Sensor 2 Pin Connector J23 Diagnostic Connector if equipped P691 J691 Electronic Unit Injectors for No 1 and No 2 Cylinders 4 Pin Connector P692 J692 Electronic Unit Injectors for No 3 and No 4 Cylin...

Page 21: ...e Manifold Temperature Sensor 11 Coolant Temperature Sensor 12 Diagnostic Connector if equipped 13 Electronic Control Module ECM i02444246 Engine Wiring Information Harness Wire Identification Perkins identifies all wires with eleven solid colors The circuit number is stamped on the wire at a 25 mm 1 inch spacing Table 6 lists the wire colors and the color codes Table 6 Color Codes for the Harness...

Page 22: ...identification of F730 OR on the schematic would signify an orange wire with the circuit number F730 F730 OR identifies the power supply for the oil pressure sensor Note Always replace a harness wire with the same gauge of wire and with the same color code ...

Page 23: ...KENR6933 23 Troubleshooting Section Schematic Diagrams g01213981 Illustration 8 Schematic Diagram for the Engine Harness ...

Page 24: ...hematic Diagram for a Typical Application i02414687 ECM Harness Connector Terminals The Electronic Control Module ECM uses connectors that have 64 terminals to interface to the wiring harness g01170706 Illustration 10 Layout of the Connector Pins view from the rear ...

Page 25: ...oval tool into the hole that is adjacent to the terminal in order to release the locking device Note Make sure that the tool stays perpendicular to the face of the connector 4 Hold the tool in position and gently pull the wire in order to remove the terminal from the rear of the connector 3 5 Remove the removal tool from the face of the connector 3 Note If a terminal must be replaced part number 2...

Page 26: ...electronic service tool will display the status of the test ECM and the hours that are remaining for the Test ECM Mode Note Test ECM Mode can only be activated if the engine serial number has not already been programmed during normal operation of the ECM If the engine serial number is programmed and the ECM is not in Test ECM Mode the ECM can never be used as a test ECM 6 Use the Copy Configuratio...

Page 27: ...n the system The Raise Resume switch for the Power Take Off PTO may be able to generate a snapshot if the option is installed If a snapshot can be generated by use of the Raise Resume switch for the PTO perform the following procedure to trigger a snapshot g00627693 Illustration 13 Typical Raise Resume Switch for the PTO 1 OFF position 2 RAISE position 3 RESUME position 1 Toggle the switch quickly...

Page 28: ...ed requires the use of factory passwords in order to clear the code from ECM memory Since factory passwords contain alphabetic characters the electronic service tool must be used to perform these functions In order to obtain factory passwords proceed as if you already have the password If factory passwords are needed the electronic service tool will request the factory passwords and the electronic...

Page 29: ...elp determine if a combustion problem is in the electronic unit injector or in the cylinder If two electronic unit injectors that are currently installed in the engine are exchanged between cylinders the injector trim files can also be exchanged Press the Exchange button at the bottom of the Injector Trim Calibration screen on the electronic service tool Select the two electronic unit injectors th...

Page 30: ... Configuration Select the type of input from the following list Analog throttle PWM throttle Communications port throttle J1939 TSC1 g01224526 Illustration 14 Typical Range of Throttle 1 Lower Diagnostic Limit Default 5 2 Lower Position Limit Default 10 3 Initial Lower Position Default 20 4 Lower Dead Zone Default 5 5 Upper Dead Zone Default 5 6 Initial Upper Position Default 70 7 Upper Position L...

Page 31: ...allowance for manufacturing tolerances between different speed demand input devices Table 11 Range Default 0 to 100 percent 0 percent Initial Lower Position Limit This is the maximum throttle percentage that will be interpreted by the ECM as zero throttle This parameter is used with the value of the lower position limit to make an allowance for manufacturing tolerances between different speed dema...

Page 32: ...nt ID is the identification of the equipment that is assigned by the customer The Equipment ID is only for reference only by the customer The Equipment ID is not required by the Electronic Control Module ECM Table 19 Value Default 17 digits The available characters are dependent on the service tool that is being used Not programmed PTO and Throttle Lock Parameters Throttle Lock Feature Installatio...

Page 33: ...d Enabled Limp Home Desired Engine Speed The Limp Home Desired Engine Speed is the maximum speed of the engine when the engine has been derated Table 26 Minimum Maximum Default 700 rpm 1800 rpm 1200 rpm J1939 Continuous Fault Handling Remote Torque Speed Control Enable Status The Remote Torque Speed Control Enable Status parameter determines the way that faults will be handled by the ECM when the ...

Page 34: ...n optional switch input Programming the Fuel Water Separator Switch Installation Status parameter to Enabled notifies the ECM that a fuel water separator switch input is present on pin J1 44 When this parameter is programmed to Enabled and the fuel water separator switch closes an E232 1 or J97 15 event code will be displayed Table 30 Value Default Installed Not Installed Not Installed User Define...

Page 35: ...Engine Speed Setting 0 to 3000 rpm 0 rpm Throttle Lock Increment Speed Ramp Rate 0 to 600 rpm sec 400 rpm sec Throttle Lock Engine Set Speed Increment 0 to 200 rpm 10 rpm Miscellaneous Monitoring Mode Shutdowns Disabled Enabled Disabled Monitoring Mode Derates Disabled Enabled Enabled Limp Home Desired Engine Speed 700 to 1800 rpm 1200 rpm J1939 Continuous Fault Handling Remote Torque Speed Contro...

Page 36: ...ock Feature Installation Status Throttle Lock Increment Speed Ramp Rate Throttle Lock Engine Set Speed Increment Miscellaneous Monitoring Mode Shutdowns J1939 Continuous Fault Handling Remote Torque Speed Control Enable Status Configurable Inputs Overspeed Protection Configurable Governor Droop Coolant Level Sensor Air Filter Restriction Switch Installation Status Fuel Water Separator Switch Insta...

Page 37: ...rtification has a different code to all other horsepower ratings and emission certifications When an ECM is replaced this rating interlock code must match the code that is stored in the ECM If the rating interlock code does not match the code that is stored in the ECM both of the following situations will exist The engine will not run Diagnostic code 0253 02 Personality Module mismatch will be act...

Page 38: ... alternator drive pulley and then inspect the nut and the drive shaft If no damage is found install the nut and tighten the nut to the correct torque Refer to Specifications Alternator and Regulator for the correct torque Alternator Bearings Check for excessive play of the shaft in the alternator Check for wear in the alternator bearings The alternator is a nonserviceable item The alternator must ...

Page 39: ...y being left in the ON position 2 Charge the battery 3 Verify that the battery is able to maintain a charge when all auxiliary devices are switched off i02453228 Can Not Reach Top Engine RPM Note If this fault occurs only under load refer to Troubleshooting Low Power Probable Causes Diagnostic codes ECM parameters Signal for the Speed demand input Air intake and exhaust system Valve lash Turbochar...

Page 40: ... turbocharger is not blocked or restricted 3 Check that the compressor housing for the turbocharger is free of dirt debris and damage 4 Check that the turbine housing for the turbocharger is free of dirt debris and damage 5 Check that the turbine blades rotate freely in the turbocharger 6 Ensure that the wastegate on the turbocharger is adjusted correctly Refer to Testing and Adjusting Turbocharge...

Page 41: ...electronic service tool to isolate one cylinder at a time Note if there is any reduction in engine speed If a reduction in engine speed is not noted the isolated cylinder is not operating under normal conditions If the isolation of a particular cylinder results in a reduction of engine speed that is less than normal this may indicate that the cylinder is operating below normal performance Investig...

Page 42: ...cause of the leakage Refer to Testing and Adjusting Cylinder Head Inspect for the correct procedure 3 Check the internal core plugs in the cylinder head for signs of leakage 4 If the cylinder head is flat and if the cylinder head does not have any faults refer to Cylinder Block Cylinder Block Inspect the top face of the cylinder block for faults and signs of leakage If a fault is found replace the...

Page 43: ... or replace the drive belt Refer to Disassembly and Assembly Alternator Belt Remove and Install 3 Check the engine cooling fan for damage If necessary replace the fan Refer to Disassembly and Assembly Fan Remove and Install Coolant Pump 1 Inspect the impeller of the coolant pump for damage and or erosion 2 Make sure that the drive gear is not loose on the drive shaft of the coolant pump 3 If neces...

Page 44: ...ration for the communications adapter Electrical connectors Communication adapter and or cables Electrical power supply to the service tool connector Electronic service tool and related hardware Electrical power supply to the Electronic Control Module ECM Perkins Data Link Recommended Actions Start the engine If the engine starts but the ECM will not communicate with the electronic service tool co...

Page 45: ... different engine If the same problem occurs on a different engine check the electronic service tool and the related hardware in order to determine the cause of the fault Electrical Power Supply to the Electronic Control Module ECM Check power to the ECM Refer to Testing and Adjusting Charging System Test Note If the ECM is not receiving battery voltage the ECM will not communicate Perkins Data Li...

Page 46: ...ntake and exhaust systems for the following defects Blockages Restrictions Damage to lines or hoses 4 Repair any defects before attempting to restart the engine 5 Attempt to start the engine If the engine will not start proceed to Diagnostic Codes Diagnostic Codes 1 Connect the electronic service tool to the diagnostic connector 2 Check for active diagnostic codes on the electronic service tool 3 ...

Page 47: ...he secondary speed timing sensor is greater than 0 rpm connect a test ECM and then attempt to start the engine If the engine starts install a replacement ECM If the engine will not start install the original ECM and then proceed to High Pressure Fuel System 4 If the pressure demand for the fuel rail is greater than 20 MPa 2900 psi proceed to High Pressure Fuel System High Pressure Fuel System 1 Us...

Page 48: ...jector and then attempt to start the engine If the engine will not start check the injection timing of the fuel rail pump Refer to Systems Operation Testing and Adjusting Fuel Injection Timing Check c If the injection timing is correct and the engine will not start proceed to Glow Plugs d If the timing of the fuel rail pump is incorrect adjust the timing Refer to Systems Operation Testing and Adju...

Page 49: ...ound investigate the cause Leaks in Air Intake System A leak in the air intake system may allow unfiltered air into the engine Inspect the air intake system for streaks which may indicate a leakage of unfiltered air Inspect all of the gaskets and the connections Repair any leaks Refer to Testing and Adjusting Air Intake System for more information Dirt in Fuel 1 Remove the fuel filters Inspect the...

Page 50: ...and Adjusting Engine Valve Lash Inspect and Adjust 2 If the repair does not eliminate the fault proceed to Fuel Supply Fuel Supply 1 Visually check the fuel tank for fuel The fuel gauge may be faulty 2 Ensure that the fuel supply valve if equipped is in the full OPEN position 3 If the temperature is below 0 C 32 F check for solidified fuel wax 4 Check the primary filter water separator for water i...

Page 51: ...blems were detected proceed to Electronic Unit Injectors Electronic Unit Injectors 1 With the engine speed at a fast idle use the electronic service tool to isolate one cylinder at a time Note if there is any reduction in engine speed If a reduction in engine speed is not noted the isolated electronic unit injector is not operating under normal conditions If the isolation of a particular cylinder ...

Page 52: ...faults and signs of leakage If a fault is found replace the cylinder block If signs of leakage are found determine the cause of the leakage Refer to Testing and Adjusting Cylinder Block Inspect for the correct procedure Assembly after Repair 1 Install the cylinder head Refer to Disassembly and Assembly Cylinder Head Install 2 Replenish the engine with clean engine oil to the correct level Refer to...

Page 53: ... operating below normal performance 2 If all cylinders have been checked and no faults were detected proceed to Electronic Unit Injectors Electronic Unit Injectors 1 With the engine speed at a fast idle use the electronic service tool to isolate one cylinder at a time Note if there is any reduction in engine speed If a reduction in engine speed is not noted the isolated electronic unit injector is...

Page 54: ...o rotate the crankshaft through 360 degrees in both direction If the crankshaft rotates correctly but fluid is expelled from the hole for the glow plug investigate the cause of the fluid in the cylinder 3 If the crankshaft rotates correctly and no fluid is expelled install the glow plugs Refer to Disassembly and Assembly Glow Plugs Remove and Install 4 If the engine does not rotate in Step 2 disas...

Page 55: ...ck that the oil drain for the turbocharger is not blocked or restricted 3 Check that the compressor housing for the turbocharger is free of dirt debris and damage 4 Check that the turbine housing for the turbocharger is free of dirt debris and damage 5 Check that the turbine blades rotate freely in the turbocharger 6 Ensure that the wastegate on the turbocharger is adjusted correctly Refer to Test...

Page 56: ...uspect cylinder Refer to Disassembly and Assembly Electronic Unit Injector Remove 3 Install a new electronic unit injector Refer to Disassembly and Assembly Electronic Unit Injector Install 4 Repeat the test in 1 If the fault is still apparent remove the replacement electronic unit injector and install the original electronic unit injector Refer to Disassembly and Assembly Electronic Unit Injector...

Page 57: ...Check the turbocharger for evidence of internal oil leaks 3 If necessary replace the turbocharger Refer to Disassembly and Assembly Turbocharger Remove and Disassembly and Assembly Turbocharger Install 4 Check that the repairs have eliminated the faults 5 If the repairs have not eliminated the fault proceed to Low Compression cylinder pressure Low Compression cylinder pressure 1 Perform a compress...

Page 58: ...n and Maintenance Manual 4 If the oil is of an acceptable quality refer to Operation in Cold Conditions Low Engine Temperature 1 The operating temperature of the engine will affect the rate of fuel consumption Operation of the engine below the correct temperature will increase fuel consumption Failure of the water temperature regulator can prevent the engine from operating at the correct temperatu...

Page 59: ...duction of the flow of combustion air into the engine Reduced flow of combustion air will increase the fuel consumption rate Refer to the Troubleshooting Guide Excessive Valve Lash Failure of the Primary Speed Timing Sensor If the primary speed timing sensor fails the engine will continue to operate using the signal from the secondary speed timing sensor on the fuel rail pump The secondary speed t...

Page 60: ...t Test 3 If the fault has not been eliminated proceed to Low Coolant Temperature Low Coolant Temperature Check that the water temperature regulator is operating correctly Refer to Testing and Adjusting Water Temperature Regulator Test If the water temperature regulator is operating correctly refer to Glow Plugs Glow Plugs 1 Check for proper operation of the glow plugs Refer to Testing and Adjustin...

Page 61: ...erate the engine at a reduced load or operate the engine at a reduced speed 3 When possible modify the cooling system and the air charge cooler in order to make the system suitable for local conditions Intake Air Restriction and or High Altitude Low air pressure at the air intake for the turbocharger can be caused by a restriction in the air intake or a high altitude When the pressure of the intak...

Page 62: ...rger compressor for oil a If oil is found in the inlet to the turbocharger compressor housing the oil originates from the engine crankcase breather b If oil is found in the outlet from the turbocharger compressor housing but oil is not found in the inlet to the compressor housing the oil originates from the seals for the turbocharger bearings i02518234 Intermittent Engine Shutdown Note Use this pr...

Page 63: ...ght and secured properly 7 Check the fuel filters 8 Check the diesel fuel for contamination Refer to Testing and Adjusting Fuel Quality Test 9 Check for air in the fuel system Refer to Testing and Adjusting Air in Fuel Test 10 Ensure that the fuel system has been primed Refer to Testing and Adjusting Fuel System Prime 11 Check the fuel pressure Refer to Testing and Adjusting Fuel System Pressure T...

Page 64: ...ck the fuel pressure Start the engine and then use the electronic service tool to check that the pressure in the fuel rail is more than 18000 kPa 2610 psi 12 If the repair does not eliminate the fault refer to Intake Manifold Pressure Intake Manifold Pressure 1 Use the electronic service tool to verify the intake manifold pressure 2 Turn the start switch to the ON position 3 The intake manifold pr...

Page 65: ... Install 2 If the fault is still apparent refer to Piston Cooling Jets Piston Cooling Jets 1 Inspect the piston cooling jets for damage Replace any piston cooling jet that appears to be cracked broken or missing Refer to Disassembly and Assembly Piston Cooling Jets Remove and Install 2 If no damage is found refer to Engine Oil Suction Tube Engine Oil Suction Tube 1 Check the inlet screen on the oi...

Page 66: ...4 Run the engine until the speed is equal to the maximum no load speed 5 Use the electronic service tool to make sure that the throttle is set to reach the maximum no load speed 6 If the maximum no load speed can not be obtained refer to Troubleshooting Throttle Switch Circuit Test and Troubleshooting Mode Selection Circuit Test 7 If the engine speed is erratic refer to Troubleshooting Analog Thro...

Page 67: ...pair does not eliminate the fault refer to Low Compression Cylinder Pressure Low Compression Cylinder Pressure 1 Perform a compression test Refer to Testing and Adjusting Compression Test 2 If low compression is noted on any cylinders investigate the cause and rectify any faults Possible causes of low compression are shown in the following list Loose glow plugs Faulty piston Faulty piston rings Wo...

Page 68: ...mage camshaft valve springs lifters pushrods and bridges Thoroughly clean the valve train components If the camshaft is being replaced also replace the valve lifters Ensure that all of the valves move freely Replace any damaged parts 2 If the mechanical noise is still apparent refer to Pistons Pistons 1 Inspect the pistons for damage and wear Replace any damaged parts 2 If the mechanical noise is ...

Page 69: ...tor is not operating under normal conditions If the isolation of a particular cylinder results in a reduction of engine speed that is less than normal this may indicate that the electronic unit injector is operating below normal performance 2 Remove the electronic unit injector from the suspect cylinder Refer to Disassembly and Assembly Electronic Unit Injector Remove 3 Install a new electronic un...

Page 70: ... Injector open circuit 653 5 113 0003 06 Cylinder 3 Injector short 653 6 113 0003 07 Cylinder 3 Injector Not Responding 653 7 113 0004 02 Cylinder 4 Injector Data Incorrect 654 2 114 0004 05 Cylinder 4 Injector open circuit 654 5 114 0004 06 Cylinder 4 Injector short 654 6 114 0004 07 Cylinder 4 Injector Not Responding 654 7 114 0005 02 Cylinder 5 Injector Data Incorrect 655 2 115 0005 05 Cylinder...

Page 71: ...ming Offset fault 637 11 143 0262 03 5 Volt Sensor DC Power Supply short to batt 1079 03 516 0262 04 5 Volt Sensor DC Power Supply short to ground 1079 04 516 0268 02 Check Programmable Parameters 630 02 527 0342 08 Secondary Engine Speed signal abnormal 723 08 142 0526 05 Turbo Wastegate Drive current low 1188 05 177 0526 06 Turbo Wastegate Drive current high 1188 06 177 0526 07 Turbo Wastegate D...

Page 72: ...ear on the electronic service tool The indicator lamps will flash the diagnostic code For more information on flash codes refer to Troubleshooting Indicator Lamps Possible Performance Effect None There are no faults that require troubleshooting Results OK STOP i02655551 CID 0001 FMI 02 Conditions Which Generate This Code The Electronic Control Module ECM detects the following condition Data from t...

Page 73: ... electronic unit injector Perform the following diagnostic procedure Injector Solenoid Circuit Test Results OK STOP i02748548 CID 0001 FMI 06 Conditions Which Generate This Code This diagnostic code is designed to indicate a short circuit high current in either the solenoid or the wiring for the electronic unit injector for No 1 cylinder The Electronic Control Module ECM detects the following cond...

Page 74: ...tive No 0041 diagnostic codes are active No 0262 diagnostic codes are active Diagnostic code 0190 08 is not active No 0110 diagnostic codes are active System Response If equipped the warning light will come on An active diagnostic code will be generated The ECM will log the diagnostic code Possible Performance Effect The engine will be derated while this diagnostic code is active Troubleshooting P...

Page 75: ...a low reading in comparison with the other electronic unit injectors An electrical fault can prevent the electronic unit injector from operating A short circuit in the wiring or the ECM that is unique to one electronic unit injector will prevent that individual electronic unit injector from operating A short circuit in common wiring within the ECM can prevent the three electronic unit injectors th...

Page 76: ...have low power and or rough running Troubleshooting When an injector cutout test is performed a faulty electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors An electrical fault can prevent the electronic unit injector from operating An open circuit in the wiring that is unique to the electronic unit injector will prevent that individual electro...

Page 77: ...ervice tool Possible Performance Effect The engine will be derated by 20 Troubleshooting Replace the suspect electronic unit injector Refer to Disassembly and Assembly Electronic Unit Injector Remove and Disassembly and Assembly Electronic Unit Injector Install Use the electronic service tool to perform the fuel system verification test Perform the following diagnostic procedure None Results OK ST...

Page 78: ...njector for No 4 cylinder The Electronic Control Module ECM detects the following conditions A high current condition short circuit for each of five consecutive attempts to operate Battery voltage above 9 volts for 2 seconds System Response If equipped the warning light will come on The ECM will log the diagnostic code Possible Performance Effect The engine will have low power and or rough running...

Page 79: ... 0005 FMI 05 Conditions Which Generate This Code This diagnostic code is designed to indicate an open circuit low current in either the solenoid or the wiring for the electronic unit injector for No 5 cylinder The Electronic Control Module ECM detects the following condition A low current condition open circuit for each of five consecutive attempts to operate Battery voltage is higher than 9 volts...

Page 80: ...ating The ECM will continue to attempt to operate the electronic unit injector after the diagnostic code has been logged but a short circuit will prevent the operation of the electronic unit injector Perform the following diagnostic procedure Injector Solenoid Circuit Test Results OK STOP i02752010 CID 0005 FMI 07 Conditions Which Generate This Code The electronic unit injector is no longer capabl...

Page 81: ...or will prevent that individual electronic unit injector from operating An open circuit in common wiring within the ECM can prevent the three electronic unit injectors that share that common wiring from operating The ECM will continue to attempt to operate the electronic unit injector after the diagnostic code has been logged but an open circuit will prevent the operation of the electronic unit in...

Page 82: ...tem verification test Perform the following diagnostic procedure None Results OK STOP i02752015 CID 0041 FMI 03 Conditions Which Generate This Code The Electronic Control Module ECM detects the following conditions The 8 volt supply is more than 8 8 VDC for more than one second The ECM has been powered for more than three seconds Diagnostic code 0168 01 is not active System Response The ECM will l...

Page 83: ...iewed on the electronic service tool The ECM will return the engine to low idle Possible Performance Effect Low power Reduced engine speed Troubleshooting Monitor the configuration screen on the electronic service tool in order to determine the type of speed demand circuit that is used on the engine If the engine is equipped with an analog speed demand circuit proceed to Test Step 1 If the engine ...

Page 84: ... will trigger a snapshot The diagnostic code will be logged if the engine is running The diagnostic code will not be logged if the engine is cranking Possible Performance Effect The engine may remain at low idle while the diagnostic code is active Troubleshooting This diagnostic code indicates that the frequency of a digital throttle signal is out of the normal range Perform the following diagnost...

Page 85: ...ensor Open or Short Circuit Test Results OK STOP i02655616 CID 0100 FMI 10 Conditions Which Generate This Code The Electronic Control Module ECM detects the following conditions No other codes for the oil pressure sensor are active No 0262 diagnostic codes are active for the 5 Volt supply The engine speed is greater than 600 rpm The engine oil pressure signal is within the limits of 410 kPa 59 psi...

Page 86: ...nt temperature sensor is less than 0 2 Volts DC for more than eight seconds The ECM has been powered for at least two seconds Diagnostic code 0168 01 is not active System Response The ECM will default to 90 C 194 F for engine coolant temperature Voltage Below Normal will be displayed next to the status for Engine Coolant Temperature on the electronic service tool If equipped the warning light will...

Page 87: ... engine shutdowns while the conditions that cause this diagnostic code are present Troubleshooting Perform the following diagnostic procedure Ignition Keyswitch Circuit and Battery Supply Circuit Test Results OK STOP i02655633 CID 0168 FMI 02 Conditions Which Generate This Code This condition indicates that the battery circuit for the Electronic Control Module ECM is intermittent while the engine ...

Page 88: ... to a power source Perform the following diagnostic procedure Engine Temperature Sensor Open or Short Circuit Test Results OK STOP i02655635 CID 0172 FMI 04 Conditions Which Generate This Code The Electronic Control Module ECM detects the following conditions The signal voltage from the intake manifold air temperature sensor is less than 0 2 Volts DC for more than eight seconds The ECM has been po...

Page 89: ...ooting Perform the following diagnostic procedure CAN Data Link Circuit Test Results OK STOP i02527036 CID 0247 FMI 12 Conditions Which Generate This Code The Electronic Control Module ECM detects the following conditions There is an unexpected loss of a continuous J1939 Torque Speed Controller TSC1 signal on the J1939 data link The expected continuous TSC1 signal has never been received on the J1...

Page 90: ...degrees The engine has been running for more than five seconds Diagnostic code 0190 08 is not active No 0041 diagnostic codes are active System Response This code will not be logged If equipped the warning light will be on when this code is active Possible Performance Effect The pressure in the fuel rail may be unstable and the engine may not run smoothly Troubleshooting Check the timing of the fu...

Page 91: ...nce and emissions are affected System Response Note The fault is not logged The electronic service tool will display a list of the condition s on the Active Diagnostics screen that must be resolved If equipped the warning light will come on Possible Performance Effect The ECM may limit the engine to low idle and or the ECM may derate the power Engine performance and emissions are affected Troubles...

Page 92: ...lator that is most likely to be an open circuit Perform the following diagnostic procedure Wastegate Solenoid Test Results OK STOP i02527044 CID 0526 FMI 06 Conditions Which Generate This Code The Electronic Control Module ECM detects the following conditions A high current condition in the output from the ECM to the solenoid in the wastegate regulator No 0168 diagnostic codes are active System Re...

Page 93: ...and the ECM will log the diagnostic code Possible Performance Effect An electrical fault may prevent the provision of pressure to the fuel rail This may result in the loss of fuel injection If the solenoid for the fuel rail pump fails it is likely that fuel will not be pumped into the fuel rail The engine will stop or the engine will not start Perform the following diagnostic procedure Fuel Rail P...

Page 94: ... is less then 0 2 VDC for at least two seconds The ECM has been powered for two seconds Diagnostic code 0168 01 is not active No 0262 codes for the 5 volt supply are active The keyswitch is in the ON position so that the ECM is energized System Response If equipped the warning light will be on The ECM will log the diagnostic code The ECM will trigger a snapshot The data for the intake manifold pre...

Page 95: ...olts DC for 0 6 seconds System Response If equipped the warning lamp will be on The ECM will log the diagnostic code The electronic service tool will display 70000 kPa next to Desired Fuel Rail Pressure and Actual Fuel Rail Pressure on the status screens Possible Performance Effect The engine will be derated Troubleshooting This code can be caused by a loss of reference ground an open signal wire ...

Page 96: ...ure Ignition Keyswitch Circuit and Battery Supply Circuit Test Results OK STOP i02527065 CID 2246 FMI 06 Conditions Which Generate This Code The Electronic Control Module ECM has detected a high current condition short circuit after attempting to activate the glow plug starting aid The ECM detects the following conditions The engine is not cranking The ECM has been powered for at least 1 second Th...

Page 97: ...locked filter may cause the engine to experience symptoms such as low power Troubleshooting The event code may represent a problem with the electronic system This event code normally indicates high air filter restriction Refer to Testing and Adjusting Manual Air Inlet and Exhaust System Inspect Results OK STOP i02536030 E232 High Fuel Water Separator Water Level Conditions Which Generate This Code...

Page 98: ... diagnostic codes for the oil pressure sensor or for the atmospheric pressure sensor Engine oil pressure is in the LEVEL 2 area in Illustration 16 for eight seconds Note The derate will be cancelled if the oil pressure rises 21 kPa 3 psi above the set point for 20 seconds 360 3 The engine has been running for at least ten seconds There are no active diagnostic codes for the oil pressure sensor or ...

Page 99: ...ll flash The ECM will generate a 46 flash code that will be displayed via the diagnostic lamp The ECM will generate a E360 3 event code The ECM will generate a SPN 100 FMI 01 event code on the J1939 data link The event code may be displayed on a receiving device on the J1939 data link Possible Performance Effect 360 1 Engine operation is not affected 360 2 The ECM will derate power by 17 0 percent...

Page 100: ...rameter has been enabled Troubleshooting Refer to Troubleshooting Coolant Temperature Is Too High Results OK STOP i02536618 E362 Engine Overspeed Conditions Which Generate This Code The engine speed is above 3000 RPM for more than 0 6 seconds Note This event code represents an event This does not represent an electronic system fault System Response The event code will be logged The optional warnin...

Page 101: ...3479 E398 Low Fuel Rail Pressure Conditions Which Generate This Code The Electronic Control Module ECM detects a problem with low fuel rail pressure The ECM detects the following problem The ECM determines that the expected fuel rail pressure is lower than the pressure that is requested by the electronic control system Diagnostic code 0262 03 5 Volt Sensor DC Power Supply voltage above normal is n...

Page 102: ...ormal is not active Diagnostic code 0172 04 Intake Manifold Air Temperature voltage below normal is not active Table 36 Intake Manifold Air Temperature Trip Level Table E539 1 E539 2 Turbocharged Engines T 139 C 282 F 142 C 287 F Turbocharged Aftercooled Engines TA 82 C 179 F 86 C 186 F Delay to Activation 8 seconds 8 seconds Reset Time 4 seconds 4 seconds System Response The event code will be lo...

Page 103: ...is code will be generated System Response The event code will be active and the event code will be logged The optional shutdown lamp will be illuminated The optional warning lamp will be illuminated If the optional shutdown feature is enabled then the engine will be shutdown Possible Performance Effect E2143 3 If the application has enabled the optional shut down feature then the engine will shut ...

Page 104: ...s DC to the following sensors Fuel Rail Pressure Sensor through connector P228 Intake Manifold Pressure Sensor through connector P200 Engine Oil Pressure Sensor through connector P201 Analog Throttle Demand Sensors if equipped through P1 OEM connector The supply for the 5 Volt engine pressure sensor is routed from the ECM through the P2 connector to terminal 1 of each pressure sensor connector The...

Page 105: ... Pressure Sensor Oil Pressure Sensor 1 Volts 5 Volts 48 46 47 2 Ground 40 38 39 3 Signal 51 55 56 Table 38 P1 OEM Connector Sensor Pin Function Analog Throttle Sensor 1 Analog Throttle Sensor 2 A 5 Volt Sensor Supply 41 42 B Ground 33 34 C Signal 54 55 g01249575 Illustration 18 Typical example of the schematic for the sensors ...

Page 106: ...ssure sensor 1 Voltage supply Vs 2 Ground GND 3 Signal SIG g01173225 Illustration 20 Typical example of the intake manifold pressure sensor 1 Voltage Supply Vs 2 Ground GND 3 Signal SIG g01173226 Illustration 21 Typical example of the oil pressure sensor 1 Voltage Supply Vs 2 Ground GND 3 Signal SIG ...

Page 107: ...sor 47 Voltage supply 5 Volts Oil Pressure Sensor 48 Voltage supply 5 Volts Fuel Rail Pressure Sensor 51 Signal SIG Fuel Rail Pressure Sensor 55 Signal SIG Intake Manifold Pressure Sensor 56 Signal SIG Oil Pressure Sensor g01207347 Illustration 23 Typical example of the P1 pin locations for the analog throttle demand sensor 33 Throttle 1 ground GND 34 Throttle 2 ground GND 41 Throttle 1 voltage su...

Page 108: ...e 37 and table 38 E Check the screws for the ECM connectors for the correct torque of 5 0 N m 44 lb in Expected Result The connectors and the harness should be free of the following faults damage abrasion corrosion and incorrect attachment Results OK Proceed to Test Step 2 Not OK Repair Repair the connectors or the harness and or replace the connectors or the harness Use the electronic service too...

Page 109: ...nostic code 0262 04 is still active Repair Leave all of the sensors disconnected Proceed to Test Step 5 Test Step 4 Install a New Sensor A Remove the connector from the suspect sensor and connect the connector to a replacement sensor Do not install the replacement sensor to the engine B Use the electronic service tool in order to monitor the diagnostic codes Expected Result Diagnostic codes 0262 0...

Page 110: ... the engine ground for each of the analog throttle demand sensors Expected Result The voltage is 5 0 0 16 Volts DC Results OK The 5 Volt supply is within the expected range Proceed to Test Step 7 Not OK The voltage is greater than 5 16 Volts DC Repair Check the 5 Volt supply wire for a short to a higher voltage source Repair the 5 Volt supply wire and or replace the 5 Volt supply wire Verify that ...

Page 111: ...tion is related to this procedure The CAN Data Link is also known as J1939 Data Link The data link is an industry standard for sending data between different devices in the same application High speed data is transfered via the data link The data link cannot be accurately tested without complicated equipment The data link requires a resistance of 60 Ohms between the two wires to correctly transmit...

Page 112: ...hly inspect the harness connector P1 J1 and any other connectors in the CAN data link circuit Refer to Troubleshooting Electrical Connectors Inspect for details C Perform a 45 N 10 lb pull test on each of the wires that are associated with the CAN data link Refer to Illustration 26 D Check the harness for abrasion and pinch points from the keyswitch to the ECM Expected Result All connectors pins a...

Page 113: ...he application one or both of the terminating resistors may be located in other ECM s on the data link Measure the resistance of the two terminating resistors If one of the terminating resistors is incorrect replace the faulty terminating resistor If the two terminating resistors are between 50 and 70 Ohms proceed to Test Step 4 Result 4 The resistance is greater than 150 Ohms There may be a break...

Page 114: ...for the data link The technician must ensure that the correct connector is being tested The connection that is used is dependent on the application If the diagnostic connector is on the engine the positive data link signal will be from P2 21 to J23 D The negative data link signal will be from P2 20 to J23 E If the diagnostic connector is off the engine the positive data link signal will be from P1...

Page 115: ...ection g01244178 Illustration 27 Schematic of the diagnostic connector and the data link connector g01208535 Illustration 28 Typical view of the P2 pin locations for the diagnostic and data link connectors 20 Data link 21 Data link ...

Page 116: ...onnector to the ECM Expected Result All connectors pins and sockets should be completely coupled and or inserted The harness should be free of corrosion abrasion and or pinch points Results OK Proceed to Test Step 2 Not OK Repair Perform the following repair Repair the connectors and or the harness or replace the connectors and or the harness Ensure that all of the seals are correctly in place and...

Page 117: ... of the diagnostic connector to battery and pin B to the battery Proceed to Test Step 2 Test Step 4 Check the Battery Voltage at the Diagnostic Connector A Turn the keyswitch to the ON position B Use a multimeter in order to measure the voltage from pin A battery and pin B ground of the diagnostic connector Expected Result The voltage is between 22 0 Volts DC and 27 0 Volts DC for a 24 Volt system...

Page 118: ...unications adapter or the electronic service tool cables allows the electronic service tool to operate correctly use the following procedure a Replace the components from the old set of electronic service tool cables into the new set of cables that operate Replace one component at a time b Apply power to the electronic service tool after each of the components is replaced Use this method to find t...

Page 119: ...KENR6933 119 Troubleshooting Section g01244183 Illustration 31 Schematic of the bypass harness connector ...

Page 120: ...iring Information STOP No Repair Perform the following repair 1 Temporarily connect a test ECM Note The test ECM should be programmed with the correct software All parameters should be set to the same value as the suspect ECM 2 Remove all jumper wires and reconnect all connectors 3 Recheck the system for active diagnostic codes 4 Repeat the Test 5 If the fault is resolved with the test ECM reconne...

Page 121: ... Follow these guidelines Always use a 27610285 Removal Tool to remove the pins from the P1 P2 connectors Always use a 2900A033 Crimp Tool to service Deutsch HD and DT connectors Never solder the terminals onto the wires Always use a 28170079 Removal Tool to remove wedges from DT connectors Never use a screwdriver to pry a wedge from a connector Always use a 2900A033 Crimp Tool to service AMP seal ...

Page 122: ...entry Note It is normal to see some minor seal abrasion on connector seals Minor seal abrasion will not allow the entry of moisture If moisture or corrosion is evident in the connector the source of the moisture entry must be found and the source of the moisture entry must be repaired If the source of the moisture entry is not repaired the fault will recur Simply drying the connector will not fix ...

Page 123: ...a sharp point B Check all of the fasteners on the harness and the strain relief components on the ECM in order to verify that the harness is correctly secured Also check all of the fasteners in order to verify that the harness is not compressed Pull back the harness sleeves in order to check for a flattened portion of wire A fastener that has been overtightened flattens the harness This damages th...

Page 124: ...the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault STOP Test Step 5 Check Individual Pin Retention into the Socket g01237435 Illustration 38 Diagram for testing pin retention A Verify that the sockets provide good retention for the pins Insert a new pin into each socket one at a time in order to check for a good grip on th...

Page 125: ...tic codes and then verify that the repair eliminates the fault STOP Test Step 8 Perform the Wiggle Test on the Perkins Electronic Service Tool EST A Select the Wiggle Test from the diagnostic tests on the Perkins Electronic Service Tool EST B Choose the appropriate group of parameters to monitor C Press the Start button Wiggle the wiring harness in order to reproduce intermittent faults If an inte...

Page 126: ... output short circuit protected A short circuit to the battery will not damage the circuit inside the ECM Pull up Voltage The ECM continuously outputs a pull up voltage on the circuit for the sensor signal wire The ECM uses this pull up voltage in order to detect an open in the signal circuit When the ECM detects the presence of a voltage that is above a threshold on the signal circuit the ECM wil...

Page 127: ...ion 39 Typical example of the schematic for the sensors g01170309 Illustration 40 Fuel rail pressure sensor 1 Voltage supply Vs 2 Ground GND 3 Signal SIG g01170310 Illustration 41 Intake manifold pressure sensor 1 Voltage Supply Vs 2 Ground GND 3 Signal SIG ...

Page 128: ...e 0100 03 Engine Oil Pressure Sensor voltage above normal 0100 04 Engine Oil Pressure Sensor voltage below normal 0100 10 Engine Oil Pressure Sensor abnormal rate of change 1785 03 Intake Manifold Pressure Sensor voltage above normal 1785 04 Intake Manifold Pressure Sensor voltage below normal 1785 10 Intake Manifold Pressure Sensor abnormal rate of change 1797 03 Fuel Rail Pressure Sensor voltage...

Page 129: ... test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code E Check the screw for the ECM connector for the correct torque of 5 N m 44 lb in F Check the harness for abrasions and for pinch points from the sensors back to the ECM G Use the electronic service tool to perform a Wiggle Test The Wiggle Test will identify intermittent con...

Page 130: ...Results OK A Voltage Above Normal diagnostic code was active before disconnecting the sensor An Voltage Below Normal diagnostic code became active after disconnecting the sensor Proceed to Test Step 6 Not OK There is a short circuit between the sensor harness connector and the ECM Leave the sensor disconnected Proceed to Test Step 8 Test Step 5 Measure the Sensor Supply Voltage A Turn the keyswitc...

Page 131: ...nated the fault STOP Not OK The open circuit diagnostic code remains active when the jumper is installed The most probable location for the open circuit is in the common wire for the sensor or in the sensor signal wire of the engine harness between the ECM and the sensor Remove the jumper Proceed to Test Step 8 Test Step 8 Check the Operation of the ECM by Creating Open and Short Circuits at the E...

Page 132: ...tor or use an engine sensor harness bypass with 3 terminals Note If an engine sensor harness bypass is being made crimp a socket on one end in order to connect to the ECM Crimp either a pin or a socket on the other end as required F Insert the one end of the engine sensor harness bypass into P2 connector on the engine harness Insert the other end of the engine sensor harness bypass into the sensor...

Page 133: ...cted to the camshaft The secondary speed timing sensor detects the movement of the teeth on the speed timing wheel in the fuel rail pump The signal that is generated by the speed timing sensor is transmitted to the ECM The ECM calculates the speed and the rotational position of the engine by using the signal The secondary speed timing sensor is required for starting purposes During normal operatio...

Page 134: ...Secondary Sensor 8 Volt Supply 1 10 10 Signal 2 52 53 g01253286 Illustration 44 Schematic for the speed timing sensors g01188474 Illustration 45 Pin locations on the P2 connector for the speed timing sensors 10 Speed Timing sensor supply 8 Volts DC 52 Crankshaft speed timing sensor signal 53 Pump Cam speed sensor signal Sig ...

Page 135: ...KENR6933 135 Troubleshooting Section g01188476 Illustration 46 Sensor locations 1 Primary speed timing sensor 2 Secondary speed timing sensor ...

Page 136: ...ration 45 D Check that the ground connection on the ECM and the negative terminal on the battery are correctly installed E Check the ground connection on the ECM for abrasions and pinch points F Check the screws for the ECM connector for the correct torque of 5 0 N m 44 lb in G Check the harness for abrasion and pinch points from the suspect sensor to the ECM H Check that the suspect sensor is ins...

Page 137: ...STOP Test Step 3 Check the Harness Between the Secondary Speed Timing Sensor and the ECM A Turn the keyswitch to the OFF position B Disconnect the P2 connector Disconnect the connector for the primary speed timing sensor Disconnect the connector for the secondary speed timing sensor C Check the resistance between P2 53 to the secondary speed timing sensor terminal 2 The resistance should be less t...

Page 138: ...oceed to Test Step 7 Not OK The harness has a short circuit Repair Repair the faulty connectors or replace the faulty connectors Repair the faulty harness or replace the faulty harness Reconnect all sensor and ECM connectors Ensure that all of the seals are correctly in place Ensure that all connectors are correctly coupled Use the electronic service tool in order to clear all logged diagnostic co...

Page 139: ... electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault STOP Not OK The fault still exists Proceed to Test Step 8 Test Step 8 Check if the Replacement of the ECM Eliminates the Fault A Temporarily connect a test ECM The test ECM must be programmed with the correct software All parameters should be set to the same value of the susp...

Page 140: ...e Electronic Control Module ECM is the common connection for the engine temperature sensors The sensor common connection is shared between the temperature sensors The common line is connected to terminal 2 on each sensor connector Terminal 1 is the sensor output The signal voltage from terminal 1 of each sensor is supplied to the appropriate terminal at ECM Connector P2 J2 Pull up Voltage The ECM ...

Page 141: ...econds for activation of the diagnostic codes C Use the electronic service tool in order to verify if any of the following diagnostic codes are active or recently logged 0110 03 Engine Coolant Temperature Sensor voltage above normal 0110 04 Engine Coolant Temperature Sensor voltage below normal 0172 03 Intake Manifold Air Temperature Sensor voltage above normal 0172 04 Intake Manifold Air Temperat...

Page 142: ...heck the harness for abrasions and for pinch points from the sensor to the ECM Expected Result All connectors pins and sockets should be completely coupled and or inserted The harness should be free of corrosion abrasion and pinch points Results OK Proceed to Test Step 3 Not OK Repair the connectors or the harness and or replace the connectors or the harness Ensure that all of the seals are correc...

Page 143: ...aulty Replace the sensor Clear all logged diagnostic fault codes STOP Not OK There is a short circuit between the sensor harness connector and the ECM Leave the sensor disconnected Proceed to Test Step 6 Test Step 5 Create A Short Circuit Between The Signal And The Common Terminals At The Sensor Harness Connector A Disconnect the suspect sensor connector P100 for the coolant temperature sensor or ...

Page 144: ...sensor common connector Install the jumper on the P2 connector Install one end of the jumper at the suspect sensor signal pin Install the other end of the jumper to the P2 37 common connection for the sensors Reassemble the P2 connector to the ECM Use the electronic service tool in order to check the diagnostic codes Wait at least 10 seconds for activation of the Voltage Below Normal diagnostic co...

Page 145: ...termittent faults were found The harness and connectors appear to be OK If this test was required as part of another procedure return to that procedure and continue testing If this test has resolved the fault return the engine to service STOP Not OK At least one intermittent fault was indicated Repair Repair the harness or the connector Use the electronic service tool in order to clear all logged ...

Page 146: ...he desired fuel rail pressure for the given engine operating conditions If the fuel rail pump solenoid fails it is likely that the fuel will not be pumped into the high pressure fuel rail and engine shutdown or failure to start the engine is expected No fuel rail pressure can be observed on the status screen of the electronic service tool g01245090 Illustration 52 Typical schematic of the circuit ...

Page 147: ...s and then verify that the repair has eliminated the fault STOP Test Step 2 Check for Active Diagnostic Codes A Connect the electronic service tool to the diagnostic connector B Turn the keyswitch to the ON position C Use the electronic service tool to verify if any of the following diagnostic codes are active or recently logged 1779 05 Fuel Rail 1 Pressure Valve Solenoid current below normal 1779...

Page 148: ...e Refer to Disassembly and Assembly Manual Fuel Injection Pump Install Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault STOP Test Step 5 Check the Fuel Rail Pump Solenoid for a Short Circuit A Turn the keyswitch to the OFF position B Disconnect the fuel rail pump solenoid connector C Turn the keyswitch to the ON posi...

Page 149: ... fuel rail pump solenoid C Insert a jumper wire across P532 D Turn the keyswitch to the ON position E Use the electronic service tool in order to perform the fuel rail pump solenoid test F Use the electronic service tool in order to monitor the status screen Expected Result A 1779 06 diagnostic code is displayed Results OK The ECM and the ECM connections function The solenoid is not an open circui...

Page 150: ...r an idle timer shutdown system that interrupts electrical power to the keyswitch The engine protection shutdown system can be an aftermarket device and the idle timer shutdown system can be external to the ECM Some of these systems will not supply power to the ECM until one of the following conditions is met The engine is cranked The engine oil pressure achieves acceptable limits An override butt...

Page 151: ...pply circuit g01193796 Illustration 55 Typical rear view of the pin locations for the ignition keyswitch and battery supply circuit 1 Battery ground GND 2 Battery ground GND 3 Battery ground GND 7 Battery 8 Battery 9 Battery ground GND 10 Battery ground GND 15 Battery ground 16 Battery ground 40 Ignition key switch ...

Page 152: ...electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault STOP Test Step 2 Check for Active Diagnostic Codes or Logged Diagnostic Codes A Connect the electronic service tool to the diagnostic connector B Turn the keyswitch to the ON position C Monitor the active diagnostic code screen on the electronic service tool Check and record a...

Page 153: ...it protection for the circuit Check for continuity in the harness for the Battery from the ECM to the batteries For intermittent faults such as intermittent shutdowns that could be caused by the application wiring temporarily bypassing the application wiring may be an effective means of determining the root cause Proceed to Test Step 5 Not OK The battery voltage is out of limits Proceed to Test St...

Page 154: ...e not removed before con nection to the battery a spark may result Note The bypass harness is only for test applications This bypass harness must be removed before the application is released to the customer The bypass harness can be used in order to determine if the cause of the intermittent fault is an interruption in battery power to the ECM or to the keyswitch circuit g01245124 Illustration 56...

Page 155: ...s that interrupt power Send the application to the OEM dealer to repair STOP Not OK The symptom is still present when the bypass harness is installed Repair Connect the bypass to another battery and verify if the fault is resolved If the fault is resolved the fault is with the batteries on the application If the fault still exists temporarily connect a test ECM Remove all jumpers and replace all c...

Page 156: ...lamp 62 Low oil pressure lamp 63 Cold start lamp Test Step 1 Inspect Electrical Connectors and Wiring A Turn the keyswitch to the OFF position B Thoroughly inspect P1 OEM connector and the lamp connections Refer to Troubleshooting Electrical Connectors Inspect for details C Perform a 45 N 10 lb pull test on each of the wires in the customer connector and the Electronic Control Module ECM connector...

Page 157: ... the keyswitch to the ON position B Use the electronic service tool to select the Override function in order to switch individual lamps ON and OFF Note The Override function is contained in the Diagnostics menu of the electronic service tool C Measure the voltage at the lamp socket Expected Result The voltage should be between 12 0 Volts DC and 24 0 Volts DC Results OK The voltage is between 12 0 ...

Page 158: ...he test ECM then reconnect the suspect ECM 5 If the fault returns with the suspect ECM then replace the suspect ECM STOP i02755811 Injector Data Incorrect Test System Operation Description Use this procedure under the following situation Use this procedure for any of the following diagnostic codes 0001 02 Cylinder 1 Injector erratic intermittent or incorrect 0002 02 Cylinder 2 Injector erratic int...

Page 159: ... four cylinder engines two injectors that share a common supply indicate a diagnostic code Note Injectors 1 and 4 share a common injector driver circuit in the ECM Injectors 2 and 3 share a common driver circuit in the ECM If two injectors that share a common supply indicate a diagnostic code then this is probably caused by a faulty ECM On six cylinder engines three injectors that share a common s...

Page 160: ...ears the fault Using the electronic service tool in order to perform the Fuel System Verification Test with the suspect ECM indicates a FAIL condition Results OK The test ECM eliminates the fault and the suspect ECM indicates a FAIL condition Replace the faulty ECM Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault STO...

Page 161: ...able the solenoid circuit The ECM will periodically try to fire the injector If the short circuit remains this sequence of events will be repeated until the fault is corrected Injector Solenoid Test Use the Injector Solenoid Test on the electronic service tool to aid in diagnosing an open circuit or a short circuit diagnostic code while the engine is not running The Injector Solenoid Test will sen...

Page 162: ...7 Injector Cylinder Number 1 35 Injector Cylinder Number 1 Return 58 Injector Cylinder Number 2 34 Injector Cylinder Number 2 Return 59 Injector Cylinder Number 3 33 Injector Cylinder Number 3 Return 64 Injector Cylinder Number 4 8 Injector Cylinder Number 4 Return 63 Injector Cylinder Number 5 7 Injector Cylinder Number 5 Return 62 Injector Cylinder Number 6 6 Injector Cylinder Number 6 Return ...

Page 163: ...ch of the wires in the ECM connector that are associated with injector solenoids D Check the screw for the ECM connector for the correct torque of 5 0 N m 44 lb in E Check the harness and wiring for abrasion and for pinch points from the injectors to the ECM Expected Result All connectors pins and sockets are completely coupled and or inserted and the harness is free of corrosion of abrasion and o...

Page 164: ...erature C Stop the engine D Turn the keyswitch to the ON position E Access the Injector Solenoid Test by accessing the following display screens in order Diagnostics Diagnostic Tests Injector Solenoid Test F Activate the test Note Do not confuse the Injector Solenoid Test with the Cylinder Cutout Test The Cylinder Cutout Test is used to shut off fuel to a specific cylinder while the engine is runn...

Page 165: ... turned OFF B Disconnect the connectors from the valve cover base C Turn the keyswitch to the ON position D Fabricate a jumper wire 100 mm 4 inch long with terminals on both ends of the wire E Insert one end of the jumper wire into the terminal for the suspect injector s supply Insert the other end of the jumper wire into the terminal for the suspect injector s return circuit F Perform the Injecto...

Page 166: ...e return wire for the suspect injector from connector P2 Install a jumper wire into connector P2 in order to provide a short between the supply and the return of the suspect injector D Reinstall connector P2 to the ECM E Turn the keyswitch to the ON position F Perform the Injector Solenoid Test at least two times Expected Result The electronic service tool displays Current Above Normal for the cyl...

Page 167: ...the diagnostic codes for supply voltage to the sensors will be active This is normal Clear all of the logged diagnostic codes after completing this test step Results OK The short circuit is in the engine harness Repair The fault is most likely in one of the wires to the injector Inspect the connectors for moisture and for corrosion Also check the wire insulation for damage and for strands that are...

Page 168: ...the ECM C Locate the terminal for the supply of the faulty injector in the connector P2 Measure the resistance from the terminal to the engine ground stud Expected Result The resistance is greater than 10 Ohms Results OK The resistance is greater than 10 Ohms Repair Reconnect connector P2 Replace the faulty injector Perform the Injector Solenoid Test Use the electronic service tool in order to cle...

Page 169: ...d throttle These terms will still be displayed on the electronic service tool for this application Use the Perkins EST in order to check the input status Table 40 P1 Pin Connections Function Throttle 1 Device Ground 33 Throttle Position Input 54 g01232661 Illustration 65 Schematic of the analog speed demand device g01228119 Illustration 66 Typical view of the P1 OEM connector pin locations 33 Devi...

Page 170: ...91 04 RESULT 2 The Perkins EST displays no active diagnostic codes Results Result 1 Proceed to Test Step 3 Result 2 There may be an intermittent connection in the wiring Proceed to Test Step 3 Test Step 3 Check the Control Signal A Refer to the OEM supplied manual for the control system B Check that the output signal from the control system is correct Expected Result The output signal from the con...

Page 171: ...ault STOP i02460763 Speed Demand Circuit Digital Test System Operation Description Use this procedure under the following conditions Use this procedure if the following diagnostic code is indicated 91 08 Throttle Position Signal Abnormal Also use this procedure if the digital speed demand device is suspected of improper operation Digital Speed Demand Signal The digital speed demand device is used ...

Page 172: ...ctor on the digital speed demand device Refer to Troubleshooting Electrical Connectors Inspect for details B Perform a 45 N 10 lb pull test on each of the wires in the ECM connector that are associated with the digital speed demand device P1 33 P1 53 C Check the screw for the ECM connector for the correct torque of 5 0 N m 44 lb in D Check the harness for abrasion and pinch points from the digital...

Page 173: ... incorrectly configured Repair Repair the control system or configure the control system Refer to the OEM supplied manual Verify that the repair eliminates the fault STOP Test Step 4 Check the Signal at the ECM A Turn the keyswitch to the OFF position B Remove the P1 OEM connector C Temporarily remove the pin from P1 53 D Reconnect P1 OEM connector E Connect the red probe of a multimeter to the re...

Page 174: ...witch power to the glow plugs If a Wait To Start lamp is installed the lamp will be illuminated in order to indicate the Wait To Start period Wait to Start Start Aid Active Lamp This feature may be included as an option On a cold start when the ECM decides that it is necessary for the glow plugs to be activated prior to starting a lamp output will indicate that the operator needs to Wait to Start ...

Page 175: ... Illustration 69 Typical schematic for the starting aid switch g01205132 Illustration 70 Typical view of the pin locations on the P1 connector 1 Ground GND 2 Ground GND 3 Ground GND 9 Ground GND 10 Ground GND 57 Start aid control 63 Cold start lamp ...

Page 176: ...nect the electronic service tool to the diagnostic connector B Turn the keyswitch to the ON position Do not start the engine C Use the electronic service tool to select the Glow Plug Override Test in order to turn on the power for the glow plugs D Check for active diagnostic codes or recently logged diagnostic codes Expected Result The following diagnostic code is active or recently logged 2246 06...

Page 177: ...ch to the ON position Note The engine has not been started at this Test Step G Use the electronic service tool in order to operate the glow plugs H Measure the voltage from the battery ground and terminal B on the glow plug start aid relay Expected Result The keyswitch is in the OFF position The voltage should be 0 Volts DC The keyswitch is in the ON position The measured voltage for the 12 Volt s...

Page 178: ...egate Typically the wastegate is a mechanical valve that is used in the turbocharger in order to regulate the intake manifold pressure to a set value The control system for the electronically controlled wastegate precisely regulates the intake manifold pressure by using a wastegate regulator to control the wastegate The required intake manifold pressure is calculated by the software that is contai...

Page 179: ...chematic for the wastegate regulator g01245711 Illustration 72 Wastegate regulator connector 1 Ground GND 2 Signal SIG g01172793 Illustration 73 Typical view of the pin locations on the P1 connector 17 Wastegate pulse width modulation PWM signal 44 Wastegate return ...

Page 180: ... Result All connectors pins and sockets are completely coupled and or inserted and the harness is free of corrosion abrasion and pinch points Results OK The harness is OK Proceed to Test Step 3 Not OK There is a fault in the connectors and or the harness Repair Repair the connectors or the harness or replace the connectors or the harness Ensure that all of the seals are correctly installed and ens...

Page 181: ...agnostic code open circuit is still active Proceed to Test Step 5 Test Step 5 Create a Short Circuit at the ECM A Turn the keyswitch to the OFF position B Temporarily remove the wires from P2 17 and P2 44 C Fabricate a jumper wire between P2 17 and P2 44 in order to create a short circuit Note The P2 J2 connector must be connected during the next step D Turn the keyswitch to the ON position Access...

Page 182: ...emove the wires from P2 17 and P2 44 in order to create an open circuit at the ECM C Turn the keyswitch to the ON position Access the Diagnostics Tests on the electronic service tool Activate the Turbo Wastegate Solenoid Test Wait at least 30 seconds in order for the result to be displayed D Check for active diagnostic codes on the electronic service tool Expected Result Diagnostic code 526 5 is n...

Page 183: ...68 FMI 00 86 CID 0168 FMI 01 87 CID 0168 FMI 02 87 CID 0172 FMI 03 88 CID 0172 FMI 04 88 CID 0190 FMI 08 89 CID 0247 FMI 09 89 CID 0247 FMI 12 89 CID 0253 FMI 02 90 CID 0261 FMI 11 90 CID 0262 FMI 03 90 CID 0262 FMI 04 91 CID 0268 FMI 02 91 CID 0342 FMI 08 91 CID 0526 FMI 05 92 CID 0526 FMI 06 92 CID 0526 FMI 07 92 CID 1779 FMI 05 93 CID 1779 FMI 06 93 CID 1785 FMI 03 93 CID 1785 FMI 04 94 CID 178...

Page 184: ...e Temperature Sensor Open or Short Circuit Test 140 Engine Vibration 52 Probable Causes 52 Recommended Actions 52 Engine Will Not Crank 53 Probable Causes 53 Recommended Repairs 53 Engine Wiring Information 21 Harness Wire Identification 21 Schematic Diagrams 23 Event Codes 97 Excessive Black Smoke 54 Probable Causes 54 Recommended Actions 54 Excessive Engine Oil Consumption 56 Probable Causes 56 ...

Page 185: ...er Position Limit 31 Lower Dead Zone 31 Lower Diagnostic Limit 30 Lower Position Limit 31 Upper Dead Zone 31 Upper Diagnostic Limit 31 Upper Position Limit 31 Starting Aid Glow Plug Relay Circuit Test 174 System Configuration Parameters 37 ECM Software Release Date 37 Engine Serial Number 37 Full Load Setting 37 Full Torque Setting 37 Rating Interlock 37 System Overview 5 Diagnostic Codes 7 Passwo...

Page 186: ...186 KENR6933 Index Section ...

Page 187: ...KENR6933 187 Index Section ...

Page 188: ...Copyright 2007 Perkins Engines Company Limited All Rights Reserved Printed in U K ...

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