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(Table 107, contd)

Troubleshooting Test Steps

Values

Results

3. Create an Open Circuit at the Switch Connector

A. Turn the keyswitch to the OFF position.

B. Disconnect the harness connector for the oil pressure
switch.

C. Turn the keyswitch to the ON position. Do not start the
engine.

D. Use the electronic service tool to check for an active 100-2
diagnostic code. Wait at least 10 seconds for activation of the
diagnostic code.

Diagnostic
codes

Result:

A 100-2 diagnostic code is active with the switch

disconnected.

Replace the oil pressure switch. Refer to Disassembly and As-
sembly, “Engine Oil Pressure Switch - Remove and Install”.
Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.

Result:

A 100-2 diagnostic code is not active with the oil pres-

sure switch disconnected.

Reconnect the harness connector for the oil pressure switch
and proceed to Test Step 4.

4. Create an Open Circuit at the ECM Connector

A. Disconnect the P2 connector from the ECM.

B. Turn the keyswitch to the ON position. Do not attempt to
start the engine. Wait at least 30 seconds for activation of the
diagnostic codes.

C. Use the electronic service tool to check for an active 100-2
diagnostic code.

Note:

Diagnostic codes for all of the engine sensors will be ac-

tive with the P2 connector disconnected. Ignore all other co-
des and only look for a 100-2 diagnostic code.

D. Turn the keyswitch to the OFF position.

Diagnostic
codes

Result:

A 100-2 diagnostic code is active with the P2 connector

disconnected.

The fault is in the wiring between the oil pressure switch and
the P2 ECM connector.
Check all wiring between the oil pressure switch and the ECM.
Refer to the appropriate Electrical Schematic.
Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.

Result:

A 100-2 diagnostic code is not active with the wire

disconnected.

Proceed to Test Step 7.

5. Create a Short at the Switch Connector

A. Turn the keyswitch to the OFF position.

B. Disconnect the harness connector for the oil pressure
switch.

C. Fabricate a jumper wire and install the jumper wire between
the harness connector for the oil pressure switch and a suit-
able ground.

D. Turn the keyswitch to the ON position. Do not start the
engine.

E. Use the electronic service tool to check for an active 100-2
diagnostic code. Wait at least 10 seconds for activation of the
diagnostic code.

F. Turn the keyswitch to the OFF position.

G. Remove the jumper wire.

Diagnostic
codes

Result:

A 100-2 diagnostic code is not active with the jumper

installed.

Replace the oil pressure switch. Refer to Disassembly and As-
sembly, “Engine Oil Pressure Switch - Remove and Install”.
Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.

Result:

A 100-2 diagnostic code is active with the jumper

installed.

Proceed to Test Step 6.

(continued)

224

UENR0612

Circuit Tests

This document has been printed from SPI2. NOT FOR RESALE

Summary of Contents for 854E-E34TA

Page 1: ...Troubleshooting 854F E34T and 854E E34TA Industrial Engines JR Engine JS Engine JT Engine UENR0612 06 February 2015 This document has been printed from SPI2 NOT FOR RESALE...

Page 2: ...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...

Page 3: ...Is Not Obtained 74 Engine Vibration Is Excessive 77 Exhaust Has Excessive Black Smoke 79 Exhaust Has Excessive White Smoke 82 Exhaust System Contains Coolant 85 Exhaust System Contains Oil 86 Fuel Con...

Page 4: ...ectronic Service Tool Does Not Communicate 239 ECM Software Install 241 ECM Replace 242 Electrical Connectors Inspect 243 Injector Code Calibrate 246 Index Section Index 248 4 UENR0612 Table of Conten...

Page 5: ...for the ECM The flash file contains the operating maps The operating maps define the following characteristics of the engine Horsepower Torque curves Engine speed rpm Refer to Troubleshooting System...

Page 6: ...rocedure must be followed This procedure minimizes the risk to the electronic components 1 Stop the engine Remove the electrical power from the ECM 2 Ensure that the fuel supply to the engine is turne...

Page 7: ...odes and logged diagnostic codes Logged events Histograms The Electronic Service Tool can also be used to perform the following functions Diagnostic tests Calibrations Programming of flash file Parame...

Page 8: ...communicate with the Electronic Control Module ECM refer to the diagnostic procedure Troubleshooting Electronic Service Tool Does Not Communicate Connecting the Electronic Service Tool and the CA3 Kit...

Page 9: ...formance and for the fuel economy Actual timing and desired timing cannot be viewed with the electronic service tool The ECM determines the location of top center of the number one cylinder from the s...

Page 10: ...n Electronic Control Circuit Diagram Illustration 4 g03746141 Electronic control circuit diagram for the 854E E34TA model JR engine 10 UENR0612 Electronic System Overview This document has been printe...

Page 11: ...Illustration 5 g03746149 Electronic control circuit diagram for the 854F E34T model JS engine UENR0612 11 Electronic System Overview This document has been printed from SPI2 NOT FOR RESALE...

Page 12: ...Illustration 6 g03746150 Electronic control circuit diagram for the 854F E34T model JT engine 12 UENR0612 Electronic System Overview This document has been printed from SPI2 NOT FOR RESALE...

Page 13: ...e connector optional 2 62 pin engine interface connector optional 3 Fuel rail pressure sensor 4 Fuel temperature sensor 5 High pressure fuel pump inlet metering valve 6 Oil pressure switch 7 Primary s...

Page 14: ...tor optional 2 62 pin engine interface connector optional 3 Fuel rail pressure sensor 4 Fuel temperature sensor 5 High pressure fuel pump inlet metering valve 6 Oil pressure switch 7 Primary speed tim...

Page 15: ...gine typical example 9 Intake manifold air pressure and temperature sensor 10 Exhaust temperature sensor connector 11 Exhaust gas pressure sensor 12 NOx Reduction System NRS valve 13 Wastegate regulat...

Page 16: ...S engine and 854F E34T model JT engine 15 Intake manifold temperature sensor 16 Intake manifold pressure sensor 17 Exhaust gas pressure sensor 18 NOx Reduction System NRS valve 19 Wastegate regulator...

Page 17: ...ical connection locations on the front of the engine 21 Intake throttle valve 22 Coolant temperature sensor 23 Secondary camshaft speed timing sensor UENR0612 17 Electronic System Overview This docume...

Page 18: ...temperature sensor 26 Inlet connection for the DPF differential pressure sensor 27 Outlet connection for the DPF differential pressure sensor Illustration 13 g03356028 Typical view of the sensor loca...

Page 19: ...onic service tool to perform the following activities for the monitoring system Viewing parameters Parameter programming Set delay times The default settings for the parameters are programmed at the f...

Page 20: ...Connectors for the Electronic Control Module ECM Illustration 14 g03747067 View of the engine ECM 1 J1 ECM connector 2 J2 ECM connector 20 UENR0612 Electronic System Overview This document has been p...

Page 21: ...n 15 g02277053 View of the J1 ECM connector ECM side Illustration 16 g02266273 View of the J2 ECM connector ECM side UENR0612 21 Electronic System Overview This document has been printed from SPI2 NOT...

Page 22: ...m Configuration Parameters System configuration parameters affect the emissions of the engine or the power of the engine Factory passwords may be required to change the values of system configuration...

Page 23: ...Intake Manifold 1 Pressure Voltage Above Normal Sensor Signal Analog Active Test 102 4 Engine Intake Manifold 1 Pressure Voltage Below Normal Sensor Signal Analog Active Test 102 20 Engine Intake Mani...

Page 24: ...Engine Air Inlet Temperature Voltage Above Normal Sensor Signal Analog Passive Test 172 4 Engine Air Inlet Temperature Voltage Below Normal Sensor Signal Analog Passive Test 173 3 Engine Exhaust Gas...

Page 25: ...Engine Injector Cylinder 04 Current Above Normal Injector Solenoid Test 654 20 Engine Injector Cylinder 04 Data Drifted High Injector Data Incorrect Test 654 21 Engine Injector Cylinder 04 Data Drifte...

Page 26: ...rpm Troubleshoot all other diagnostic codes If this code is the only active diagnostic code replace the ECM Refer to Troubleshooting ECM Replace 1239 0 Engine Fuel Leakage 1 High most severe 3 Fuel R...

Page 27: ...e Voltage Below Normal Sensor Signal Analog Passive Test 3251 0 Particulate Trap Differential Pressure High most severe 3 Diesel Particulate Filter Collects Excessive Soot 3251 3 Particulate Trap Diff...

Page 28: ...Indicator Lamp Test 5246 15 Aftertreatment SCR Operator Inducement Severity High least severe 1 See Operator Inducement Codes 5246 16 Aftertreatment SCR Operator Inducement Severity High mod erate se...

Page 29: ...or Short Circuit Test 102 20 Engine Intake Manifold 1 Pressure Data Drifted High Engine Pressure Sensor Open or Short Circuit Test 102 21 Engine Intake Manifold 1 Pressure Data Drifted Low Engine Pre...

Page 30: ...Differential Pressure Abnormal Rate of Change Diesel Particulate Filter Has Differential Pressure Problem 3251 18 Particulate Trap Differential Pressure Low moderate severity 2 Diesel Particulate Fil...

Page 31: ...not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again Note The procedures have been listed in order of probabilit...

Page 32: ...load speed cannot be obtained refer to Troubleshooting Switch Circuits Test Throttle Switch and Troubleshooting Mode Selection Test If the engine speed is erratic refer to Troubleshooting Speed Contro...

Page 33: ...Refer to Disassembly and Assembly Turbocharger Remove and Disassembly and Assembly Turbocharger Install Result The turbocharger is OK Proceed to Test Step 8 8 Fuel Supply A Visually check the fuel le...

Page 34: ...Malfunctioning Cylinders A With the engine speed at a fast idle use the electronic service tool to perform the manual Cylinder Cut Out Test As each cylinder is cut out listen for a change in the soun...

Page 35: ...ve pulley nut was loose Tighten the nut Result There is not excessive wear on the alternator drive pulley Proceed to Test Step 3 3 Wear of the Alternator Bearings A Check the alternator bearings for s...

Page 36: ...ation Testing and Adjusting Battery Test Battery Result The battery is not OK Replace the battery Refer to the Operation and Maintenance Manual Battery Replace Result The battery is OK Proceed to Test...

Page 37: ...o the Operation and Main tenance Manual for the correct procedure Refill the cooling system with the correct coolant Refer to the Operation and Maintenance Manual for the recommended coolant and capac...

Page 38: ...ylinder block In spect the top deck Refer to the Reuse and Salvage Guide lines for the proper inspection procedure Result No fault is found in the cylinder block Install the cylinder head Refer to Dis...

Page 39: ...Control Module ECM detects that the coolant temperature is greater than 112 C 233 6 F for at least 0 5 seconds The code will be reset if the coolant temperature is less than 110 C 230 F for at least 0...

Page 40: ...ses and or other restrictions C Check the radiator for internal blockage D Ensure that the radiator size is sufficient An undersized radiator does not have enough area for the effective release of hea...

Page 41: ...iator B Check the engine cooling fan for damage Fan and drive belt Result The drive belt is not tensioned correctly Result The fan is damaged Repair the fan or replace the fan as necessary Refer to Di...

Page 42: ...system Cylinder Head gasket Result Bubbles are present in the coolant or the coolant is discolored Check the cylinder head gasket Refer to the recom mended action for the cylinder head gasket within T...

Page 43: ...Causes Breather filter Breather hoses Breather heater Excessive blow by Recommended Actions Illustration 18 g02919737 UENR0612 43 Symptom Troubleshooting This document has been printed from SPI2 NOT F...

Page 44: ...he OFF position B Disconnect the breather heater connector C Turn the keyswitch to the ON position D Use a suitable multimeter to measure the voltage at the harness connector for the heater E Turn the...

Page 45: ...A Check the fuel quality Refer to Systems Operation Testing and Adjusting Fuel Quality Test B Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for th...

Page 46: ...are no active diagnostic codes for the injectors Proceed to Test Step 5 5 Pistons A Inspect the pistons for damage and wear Pistons Result One or more pistons are worn or damaged Replace any worn or d...

Page 47: ...or active diagnostic codes on the electronic service tool Diagnostic codes Result There are active diagnostic codes Investigate any active codes before continuing with this procedure Refer to Troubles...

Page 48: ...the cause of the fault on any cylinder that is not operating Investigate the cause of the fault on any cyl inder that is operating below normal performance Result There is a noticeable change in the...

Page 49: ...secure and no leaks are present Exhaust leaks Result There are exhaust leaks Make the necessary repairs Verify that the repair has elimi nated the fault Result The exhaust duct is OK Proceed to Test S...

Page 50: ...19 0 Aftertreatment 1 Diesel Particulate Filter Soot Load Percent High most severe 3 The ECM detects that the soot level in the DPF is high The warning lamp will come on 3719 16 Aftertreatment 1 Diese...

Page 51: ...tep 3 3 Exhaust Leaks A Thoroughly inspect the exhaust duct between the engine and the CEM for leaks Ensure that all connections are secure and no leaks are present B Inspect the insulation on the exh...

Page 52: ...arning lamp will come on The engine will be derated 3251 17 Particulate Trap Differential Pressure Low least severe 1 The ECM detects the following conditions There is no differential pressure across...

Page 53: ...ocedure Result A related diagnostic trouble code is not active or logged Proceed to Test Step 2 2 Exhaust Leaks A Thoroughly inspect the exhaust duct between the engine and the DPF for leaks Ensure th...

Page 54: ...lation method for the DPF DPF Result The DPF is not installed correctly Remove the DPF and install the DPF correctly Refer to Disassembly and Assembly Diesel Particulate Filter Re move andDisassembly...

Page 55: ...ssary repairs Verify that the repair has elimi nated the fault Result The exhaust duct is OK Proceed to Test Step 4 4 Wastegate A Check for correct operation of the wastegate Refer to Systems Operatio...

Page 56: ...roceed to Test Step 3 3 Visible Faults A Visually inspect the engine for the following faults Missing components Damaged components Damaged electrical cables or loose electrical cables Oil leaks Fuel...

Page 57: ...for contamination Refer to Systems Operation Testing and Adjusting Fuel Quality Test G Check for air in the fuel system Refer to Systems Opera tion Testing and Adjusting Air in Fuel Test H Ensure tha...

Page 58: ...Illustration 20 g03705140 View of the fuel manifold typical example 58 UENR0612 Symptom Troubleshooting This document has been printed from SPI2 NOT FOR RESALE...

Page 59: ...replaced use the elec tronic service tool to perform the Rail Pressure Sensor Replacement Reset Result No fuel is present in the container Proceed to Test Step 8 8 Fuel Pump Timing A Check the timing...

Page 60: ...ean the battery cables Tighten any loose connections B Inspect the batteries C Charge the batteries Test the batteries Refer to Systems Operation Testing and Ad justing Battery Test Batteries and cabl...

Page 61: ...System Test Starting motor solenoid and circuit Result The starting motor solenoid and circuit are not OK Make the necessary repairs Result The starting motor solenoid and circuit are OK Proceed to T...

Page 62: ...when a unit injector is removed A Check for fluid in the cylinders by removing the individual unit injectors Check for damaged seals B If there was excessive fuel in the cylinder replace the seals and...

Page 63: ...and stopping in cold conditions Note Frequent starting and stopping of the engine can cause early wear Also operation of the engine for short periods of time in cold conditions can cause early wear M...

Page 64: ...hydrogen sulfide and sulfur can lead to the formation of acids in the crankcase B Obtain a fuel analysis Fuel and fuel filters Result The fuel has contamination Determine the cause of any contaminatio...

Page 65: ...er procedure Fuel Result The fuel quality is not OK Note Refer to Operation and Maintenance Manual for infor mation on the proper characteristics of the fuel for the engine If necessary Replace the fu...

Page 66: ...in Result The valve train components are damaged Make the necessary repairs Verify that the repair eliminated the noise Result The valve train components are not damaged Proceed to Test Step 7 7 Gear...

Page 67: ...gine operating temperature Troubleshooting the symptoms under other conditions can give misleading results Probable Causes Diagnostic codes Air Intake and Exhaust System Fuel System Inspection Throttl...

Page 68: ...take or exhaust systems Proceed to Test Step 3 3 Fuel System Inspection A Check that the fuel shut off valve is in the OPEN position B If the temperature is below 0 C 32 F check for solidified fuel wa...

Page 69: ...placed A Use the electronic service tool to select the correct screen in or der to display any diagnostic trouble codes that relate to the fuel in jection pump HP fuel pump Result There are diagnostic...

Page 70: ...Contact the Dealer Solution Network DSN i05271038 Engine Overspeeds This procedure covers the following diagnostic code Table 29 Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Code Des...

Page 71: ...es Result There are no active codes Proceed to Test Step 2 2 Air Intake A Check the air filter for blockages or restrictions B Check the air intake duct for blockages or restrictions Blockages or rest...

Page 72: ...Refer to Sys tems Operation Testing and Adjusting Fuel System Prime Fuel System Result A defect was found in the fuel system Make any necessary repairs Result No defects found Proceed to Test Step 5 5...

Page 73: ...3 3 Fuel System Inspection A Check that the fuel shut off valve is in the OPEN position B If the temperature is below 0 C 32 F check for solidified fuel wax C Check for fuel supply lines that are res...

Page 74: ...Diagnostic codes Result There are active diagnostic codes for the fuel injectors Troubleshoot the active diagnostic codes Refer to Trou bleshooting Diagnostic Trouble Codes Result All injectors are OK...

Page 75: ...ge eliminated the fault Result The parameters are configured correctly Proceed to Test Step 4 4 Throttle Signal From the Throttle Position Sensor if equipped A If a fault is suspected in the throttle...

Page 76: ...l system Refer to Systems Opera tion Testing and Adjusting Air in Fuel Test H Ensure that the fuel system has been primed Refer to Sys tems Operation Testing and Adjusting Fuel System Prime Fuel Syste...

Page 77: ...When a cylinder is cut out there should be a no ticeable change in the sound of the engine Cylinders Result There is not a noticeable change in the sound of the engine for at least one cylinder Inves...

Page 78: ...and the balance of the driven equipment B Inspect the coupling Driven equipment Result The driven equipment and the alignment are not OK Repair or replace the driven equipment Result The driven equip...

Page 79: ...Solution Network DSN i06004613 Exhaust Has Excessive Black Smoke If excessive black smoke is caused by a fault in the engine and the engine is equipped with a wall flow Diesel Particulate Filter DPF...

Page 80: ...3 Air Intake and Exhaust System A Check the air filter restriction indicator if equipped Replace a plugged air filters Refer to the Operation and Maintenance Manual B Check the air inlet and exhaust...

Page 81: ...ect If the wastegate actuator is faulty re place the turbocharger Refer to Disassembly and Assembly Turbocharger Remove and Disassembly and Assembly Turbocharger Install Turbocharger Result There is a...

Page 82: ...re is not a noticeable change in the sound of the engine for at least one cylinder Investigate the cause of the fault on any cylinder that is not operating Investigate the cause of the fault on any cy...

Page 83: ...t Refer to Trouble shooting Glow Plug Starting Aid Test Glow plugs Result The glow plugs are not operating correctly Make the necessary repairs Verify that the repair cor rected the fault Result The g...

Page 84: ...tenance Manual Fuel System Prime Verify that the procedure has eliminated the noise Result The fuel quality is OK Proceed to Test Step 7 7 Valve Lash Note Excessive valve lash will cause a change in...

Page 85: ...each cylin der is cut out listen for a change in the sound from the engine When a cylinder is cut out there should be a noticeable change in the sound of the engine Cylinders Result There is not a not...

Page 86: ...t Refer to the Disas sembly and Assembly manual Result The cylinder head gasket is not leaking Proceed to Test Step 3 3 Cylinder head A Check for cracks in the cylinder head Perform a leak test on the...

Page 87: ...t The valve guide seals are not damaged Proceed to Test Step 4 4 Worn Valve Guides A Inspect the valve guides for wear Refer to the Specification manual for the maximum permissible wear of the valve g...

Page 88: ...uel consumption A Use the electronic service tool to check for active or logged codes Diagnostic codes Result A diagnostic code is present Troubleshoot the diagnostic code and then verify that the fue...

Page 89: ...system Refer to the Operation and Mainte nance Manual Fuel System Prime Result The fuel quality meets specifications Proceed to Test Step 5 5 Quality of Oil Note The nominal viscosity of the lubricati...

Page 90: ...eed The operating speed of the engine will affect the rate of fuel consumption High engine speed will increase fuel consumption At high en gine speeds internal power losses in the engine increase and...

Page 91: ...and closing of the inlet and exhaust valves Exces sive valve lash can cause a reduction of the flow of combustion air into the engine Reduced flow of combustion air will increase the fuel consumption...

Page 92: ...n the fuel tank and then fill the fuel tank with clean fuel Repeat the procedure from Test Step 1 3 Water In Fuel Switch A Check the operation of the Water In Fuel switch Refer to Trou bleshooting Wat...

Page 93: ...mpared to the volume of fuel that is being supplied by the fuel injection pump If equipped the warning lamp will flash and the shutdown lamp will come on The engine will be derated 5571 2 High Pressur...

Page 94: ...es Electrical connectors Fuel filters Fuel rail pressure sensor Fuel system inspection Fuel rail Pressure Relief Valve PRV High pressure fuel pump 94 UENR0612 Symptom Troubleshooting This document has...

Page 95: ...service 2 Electrical Connectors A Check for the correct installation of the ECM J1 P1 and the J2 P2 connectors Check for correct installation of the connector on the fuel rail pressure sensor Connecto...

Page 96: ...cted D Check that the low pressure fuel lines are correctly installed E Check the pressures in the fuel system Refer to Systems Oper ation Testing and Adjusting Fuel System Pressure Test F Check the d...

Page 97: ...Illustration 21 g02859420 UENR0612 97 Symptom Troubleshooting This document has been printed from SPI2 NOT FOR RESALE...

Page 98: ...hen the fuel manifold has been replaced use the electronic service tool to perform the Rail Pressure Valve Learn Reset Result No fuel is present in the container Proceed to Test Step 7 7 High Pressure...

Page 99: ...Steps Values Results 1 Check the Air Filter Element A Check the air intake system for plugged air filters or for damaged air filters If the engine is equipped with an air intake precleaner verify the...

Page 100: ...ake manifold air pressure by 50 kPa 7 25 psi for at least 10 seconds If equipped the warning lamp will flash The engine will be derated If the actual intake manifold pressure is within 25 kPa 3 6 psi...

Page 101: ...nostic codes are present that relate to the waste gate regulator Rectify the cause of any related codes Refer to Troubleshoot ing Diagnostic Trouble Codes Result There are no diagnostic codes that rel...

Page 102: ...Regulator A Use the electronic service tool to check for diagnostic trou ble codes that relate to the wastegate regulator Wastegate regulator Result Diagnostic codes are present that relate to the was...

Page 103: ...lled to the correct level Note If the coolant level is too low air will get into the cooling system Air in the cooling system will cause a reduction in coolant flow Coolant Result The coolant level is...

Page 104: ...ature is high Operate the engine at reduced speed or reduced power Result The ambient air temperature is OK Proceed to Test Step 6 6 Altitude A Check for operation at high altitude Note The cooling ca...

Page 105: ...haust Gas Recirculation EGR system The warning lamp will flash The engine may be derated Probable Causes Diagnostic codes Electrical connectors and harness Air inlet and exhaust system Recommended Act...

Page 106: ...ry are correctly installed E Check the ground connection on the ECM for abrasions and pinch points F Check the harness for abrasion and pinch points from the EGR components to the ECM H Check that any...

Page 107: ...ne hours Oil level Result The oil consumption is less than 0 1 of the fuel consumption Oil consumption is within specification Return the unit to service Result The oil consumption is greater than 0 1...

Page 108: ...A Check for a high oil level in the engine Oil level Result The oil level in the engine is high Make sure that the oil is not contaminated with fuel Refer to Troubleshooting Oil Contains Fuel Make su...

Page 109: ...nder Pressure A Perform a compression test Refer to Systems Operation Testing and Adjusting Compression Test Cylinder compression Result The results of the compression test are outside the specificati...

Page 110: ...and Assembly Engine Oil Cooler Install for the correct procedure Result No evidence of coolant in the oil system is found Proceed to Test Step 2 2 Cylinder Head Gasket A Remove the cylinder head Refe...

Page 111: ...lace the faulty core plug Result The cylinder head is OK Proceed to Test Step 4 4 Cylinder Block A Inspect the top face of the cylinder block for faults and signs of leakage Cylinder block Result The...

Page 112: ...ead verify the dilution by the following methods Gas chromatograph fuel dilution test Oil viscosity The test that uses a gas chromatograph is designed to measure fuel dilution in crankcase oils The ga...

Page 113: ...the engine oil Refer to Troubleshooting Diesel Partic ulate Filter Active Regeneration Occurrence Is Excessive Excessive regeneration Result There is excessive use of active regeneration Make any nece...

Page 114: ...ow oil pressure Engine damage will result If measured oil pressure is low discontinue engine operation until the fault is corrected The Electronic Control Module ECM monitors the engine oil pressure P...

Page 115: ...ect specification Proceed to Test Step 4 4 Engine Oil Filter A Remove the engine oil filter Refer to the Operation and Maintenance Manual Engine Oil and Filter Change B Inspect the engine oil filter f...

Page 116: ...Troubleshooting Oil Contains Fuel Result The oil is not contaminated Proceed to Test Step 9 9 Piston Cooling Jets A Inspect the piston cooling jets for cracks damage or miss ing jets Piston cooling je...

Page 117: ...not within specification Install a new bearing Refer to Disassembly and Assembly Result All engine bearings are within specification If the fault is still present there may be an open circuit conditi...

Page 118: ...e connectors have been correctly installed Electrical connectors Result An electrical connector is damaged Repair the electrical connector or replace the electrical connector Result A connector seal i...

Page 119: ...ilters A Replace the primary fuel filter and the secondary fuel filter Refer to the Operation and Maintenance Manual Fuel Sys tem Primary Filter Water Separator Element Replace B Run the engine in the...

Page 120: ...re that the passages for the engine oil are clear Result The oil flow to the valve mechanism is OK Proceed to Test Step 2 2 Valve Train Components A Inspect the following components of the valve train...

Page 121: ...s 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 transferred v...

Page 122: ...ical example of the schematic for the CAN data link Illustration 23 g03600802 Typical view of the pin locations on the P1 connector 46 CAN 47 CAN 122 UENR0612 Circuit Tests This document has been prin...

Page 123: ...it in the harness Repair the connectors or the harness and or replace the con nectors or the harness Ensure that all of the seals are cor rectly in place and ensure that the connectors are correctly c...

Page 124: ...CAN Data Link A Use the appropriate service tools in order to diagnose other de vices on the data link Other devi ces are OK Result At least one of the other devices is not operating correctly Use th...

Page 125: ...become active If equipped the warning lamp will come on 2840 12 ECU Instance Failure The ECM detects that the flash file that is installed is invalid If equipped the warning lamp will come on 5357 31...

Page 126: ...diagnostic codes relating the fuel sys tem Refer to Troubleshooting Diagnostic Trouble Codes If there are no other codes relating to the fuel system pro ceed to Test Step 3 2 Clear the Diagnostic Code...

Page 127: ...ork DSN B If the Dealer Solution Network DSN recommends the use of a replacement ECM install a replacement ECM Refer to Trouble shooting Replacing the ECM C Use the electronic service tool to recheck...

Page 128: ...ngine shutdowns while the conditions that cause this diagnostic code are present Battery voltage is supplied through P1 1 3 and 5 The battery is supplied through P1 2 4 and 6 The ECM receives the keys...

Page 129: ...r the application Illustration 25 g03722982 View of the pin locations on the P1 connector for the electrical power supply circuit 1 Battery 2 Battery ground 3 Battery 4 Battery ground 5 Battery 6 Batt...

Page 130: ...codes Result There are no active 168 diagnostic codes at this time If the fault is intermittent refer to Troubleshooting Electrical Connector Inspect If the ECM is receiving no battery voltage procee...

Page 131: ...he following conditions The diagnostic signal from the GCU indicates that there is a short in the circuit for the glow plug for cylinder number 2 5326 7 Engine Glow Plug 3 Not Responding Properly The...

Page 132: ...n 28 g02674096 View of the pin locations on the GCU 1 Glow plug cylinder 3 2 Glow plug cylinder 1 3 GCU diagnostic return 4 Battery 5 GCU ground 6 Glow plug cylinder 4 7 Glow plug cylinder 2 8 Glow pl...

Page 133: ...ool to clear all logged diagnostic co des Verify that the repair eliminates the fault Result All connectors pins and sockets are correctly con nected and or inserted and the harness is free of corrosi...

Page 134: ...n the harness connector for the suspect glow plug and the appropri ate terminal on the GCU connector Less than 5 Ohms Result At least one of the resistance measurements is greater than 5 Ohms The faul...

Page 135: ...FF position B Disconnect the GCU C Turn the keyswitch to the ON position D Measure the voltage between pin 4 and pin 5 on the har ness connector for the GCU 10 V to 14 V Result The measured voltage is...

Page 136: ...r C Measure the resistance between pin 8 on the harness con nector for the GCU and P1 52 Less than 5 Ohms Result The measured resistance is not within the expected range There is an open circuit or hi...

Page 137: ...s an open circuit or high resistance in the wiring Repair the faulty wiring or replace the faulty wiring Result The measured resistance is less than 5 Ohms Contact the Dealer Solution Network DSN i060...

Page 138: ...ired for mobile applications The IVS is part of the throttle position sensor The IVS is CLOSED when the low idle is set The configuration parameters for the throttle and for the IVS thresholds are pro...

Page 139: ...for the Idle Validation Switch IVS switch circuit Illustration 30 g03771057 View of the pin locations on the P1 connector for the IVS circuit 42 IVS 2 76 IVS 1 UENR0612 139 Circuit Tests This documen...

Page 140: ...n E Select the SERVICE option from the drop down menu of the electronic service tool F Select the Throttle Configuration option on the electronic service tool Select the appropriate Throttle Configura...

Page 141: ...ion Max ON Threshold parameters The fault appears to be resolved Return the engine to service Result The IVS switch cannot operate within the Idle Validation Min OFF Threshold and the Idle Validation...

Page 142: ...on the harness connector to P1 42 Less than 5 Ohms Result The measured resistance is less than 5 Ohms Proceed to Test Step 8 Result The measured resistance is greater than 5 Ohms There is an open cir...

Page 143: ...e shown on the electronic service tool should increase and the IVS status should change from CLOSED ON to OPEN OFF position Make a note of the raw reading for the throttle when the IVS reading changes...

Page 144: ...the new threshold limits into the electronic service tool Click Submit on the electronic service tool screen E Turn the keyswitch to the OFF position and wait at least 5 sec onds Turn the keyswitch to...

Page 145: ...Lamp Command Current Above Normal The ECM detects a high current condition in the circuit for the HEST lamp 3702 5 Diesel Particulate Filter Active Regeneration Inhibited Status Current Below Normal T...

Page 146: ...he electri cal schematic for the application STOP 2 Check the Bulb Replace the bulb with a bulb that is known to be good Test the cir cuit again Bulb Result The lamp illuminates The problem is resolve...

Page 147: ...these diagnostic codes will become active for the applicable cylinder 651 21 Engine Injector Cylinder 01 Data Drifted Low 652 20 Engine Injector Cylinder 02 Data Drifted High 652 21 Engine Injector Cy...

Page 148: ...njector Code Calibrate D Use the electronic service tool to clear all active diagnostic codes E Start the engine F Use the electronic service tool to check for active diagnostic codes G Turn the keysw...

Page 149: ...s still active Proceed to Test Step 6 6 Replace the Suspect Injector A Replace the injector for the cylinder with the XXX 20 or XXX 21 diagnostic code Refer to Disassembly and Assembly Electronic Unit...

Page 150: ...nd injector 4 The fault is present for at least five attempts to actuate the driver The ECM will log the diagnostic code The engine will have low power and or rough running The engine may shut down A...

Page 151: ...ical example of the harness connector for the fuel injectors Illustration 34 g02373216 1 Cylinder 3 injector supply 2 Cylinder 2 injector supply 16 Cylinder 1 injector supply 17 Cylinder 4 injector su...

Page 152: ...logged Diagnostic codes Result An XXXX 5 diagnostic code is active or recently logged Note the cylinders that the codes are applicable to Proceed to Test Step 3 Result An XXXX 6 diagnostic code is ac...

Page 153: ...rify that the repair eliminates the fault Result An XXX 5 diagnostic code is still active with the jumper installed Proceed to Test Step 7 5 Create an Open Circuit at the Injector Connector or Connect...

Page 154: ...eck all wiring between the suspect injector and the ECM Refer to the Electrical Schematic for the engine Replace the faulty wiring Use the electronic service tool to clear all logged diagnostic co des...

Page 155: ...5 seconds The battery voltage is at least 10 VDC The warning lamp will come on 2880 4 Engine Operator Primary Intermediate Speed Select Voltage Below Normal The ECM detects the following conditions Th...

Page 156: ...own Refer to the Electrical Schematic for the application Illustration 37 g02723018 Typical view of the pin locations on the P1 connector for the mode selection switch 55 Mode selection switch signal...

Page 157: ...eed to Test Step 5 3 Create an Open Circuit at the Switch A Turn the keyswitch to the OFF position B Disconnect the mode selection switch C Turn the keyswitch to the ON position D Use the electronic s...

Page 158: ...ms Result At least one of the resistance measurements is greater than 5 Ohms The fault is in the wiring between the switch connector and the P1 connector Replace the faulty wiring Use the electronic s...

Page 159: ...tects the following conditions A low current condition in the output for the engine intake throttle valve for at least 0 5 seconds The ECM will log the diagnostic code 5419 6 Engine Throttle Actuator...

Page 160: ...ake throttle valve position sensor 5 VDC supply 9 NRS valve position sensor 5 VDC supply 24 NRS valve position sensor ground 34 Intake throttle valve return 35 NRS valve return 37 Intake throttle valv...

Page 161: ...diagnostic code is active or recently logged for one or more of the motorized valves Proceed to Test Step 4 Result An XXXX 6 diagnostic code is active or recently logged for one or more of the motoriz...

Page 162: ...connector disconnected Ignore all other co des and only look for codes that relate to the suspect valve E Look for an active XXXX 6 diagnostic code for the suspect valve F Turn the keyswitch to the O...

Page 163: ...hooting Replac ing the ECM C Use the electronic service tool to recheck the system for ac tive diagnostic codes Diagnostic codes Result There are no active diagnostic codes with the replace ment ECM R...

Page 164: ...the oxygen sensor 3222 4 Aftertreatment 1 Intake Gas Sensor Heater Voltage Below Normal The ECM detects a short to ground in heater circuit for the oxy gen sensor 3222 5 Aftertreatment 1 Intake Gas Se...

Page 165: ...ground 86 Current adjust Illustration 42 g03114187 View of the pin locations on the harness connector for the oxygen sensor view from the front 1 Current pump 2 Virtual ground 3 Sensor heating ground...

Page 166: ...k the fuses B Thoroughly inspect the connector for the oxygen sensor Refer to Troubleshooting Electrical Connectors Inspect C Thoroughly inspect the P1 J1 ECM connector Refer to Troubleshooting Electr...

Page 167: ...rn the keyswitch to the OFF position B Disconnect the oxygen sensor C Turn the keyswitch to the ON position D Use a suitable multimeter to measure the voltage between pin 4 on the harness connector fo...

Page 168: ...er to the Electrical Schematic for the application Repair the faulty wiring or replace the faulty wiring Use the electronic service tool to clear all logged diagnostic co des Run the engine for 15 min...

Page 169: ...t Lambda Sensor Learn Reset Lambda Sensor Temperature Learn Reset C Turn the keyswitch to the ON position If the engine will start run the engine for 15 minutes D Use the electronic service tool to ch...

Page 170: ...switches was pressed for more than 10 seconds OR Two PTO switches were pressed at the same time for at least 0 5 seconds The battery voltage is at least 10 VDC The warning lamp will come on Follow th...

Page 171: ...wn fuses Use the electronic service tool to clear all logged diagnostic codes Verify that the repair eliminates the fault 2 Check for Active Diagnostic Codes A Turn the keyswitch to the OFF position B...

Page 172: ...Turn the keyswitch to the ON position D Check the voltage between the battery supply wire to the sus pect switch and a suitable ground 10 V to 14 V Result The measured voltage is within the ex pected...

Page 173: ...f the resistance measure ments is less than 1 k Ohm There is a short in the wiring between the suspect switch and the P1 ECM connector Check all wiring between the suspect switch and the ECM Refer to...

Page 174: ...starting motor relay while no start request is detected The battery voltage is between 9 5 and 16 VDC The warning lamp will come on The start relay circuit will be disabled 677 6 Engine Starter Motor...

Page 175: ...Starting motor relay control The following background information is related to this procedure When the keyswitch is turned to the START position a signal is sent to pin P1 8 on the engine ECM Power i...

Page 176: ...air eliminates the fault 2 Check for Active or Recently Logged Diagnostic Codes A Connect the electronic service tool to the diagnostic connector B If the engine will start then start the engine C Mak...

Page 177: ...the start relay P1 27 to terminal 2 on the harness connector for the start relay Less than 5 Ohms Result Each resistance measurement is less than 5 Ohms Contact the Dealer Solution Network DSN Result...

Page 178: ...t signal wiring between the ignition keyswitch and the ECM Refer to the Elec trical Schematic for the application Replace the faulty wiring Use the electronic service tool to clear all logged diagnost...

Page 179: ...attempt to start the engine F Use a suitable multimeter to measure the voltage between the start signal S terminal on the connector for the ignition key switch and a suitable ground 10 V to 14 V Resu...

Page 180: ...s detected the next time the keyswitch is turned ON The diagnostic code be comes active when the fault is detected for three consecutive starts The warning lamp will come on This condition is most lik...

Page 181: ...plication Illustration 48 g02716384 View of the pin locations on the P1 connector for the ignition keyswitch and battery supply circuit 1 Battery 2 Battery ground 3 Battery 4 Battery ground 5 Battery...

Page 182: ...repair eliminates the fault 2 Check for Diagnostic Codes A Turn the keyswitch to the OFF position B Connect the electronic service tool to the diagnostic connector C Turn the keyswitch to the ON posit...

Page 183: ...and Test Point B terminal 85 on the harness connector for the ECM main relay 0 V Result The voltage measurement is 0 VDC Contact the Dealer Solution Network DSN Result The voltage measurement indicat...

Page 184: ...at least 0 8 seconds The barometric pressure sensor is contained within the ECM The ECM will use the default value for the barometric pressure while this code is active The default val ue is 97 kPa 14...

Page 185: ...e following conditions The intake manifold pressure is greater than 7 kPa 1 psi below the barometric pressure for at least 5 seconds The engine is not cranking The battery voltage is greater than 10 V...

Page 186: ...anifold air pressure sensor 5 VDC supply 11 Fuel rail pressure sensor 5 VDC supply 25 Intake manifold air pressure sensor ground 26 Fuel rail pressure sensor ground 40 Intake manifold air pressure sen...

Page 187: ...ctive Diagnostic codes Result A 108 3 or 108 4 diagnostic code is active Proceed to Test Step 9 Result An XXXX 3 or an XXXX 4 diagnostic code is active for one or more of the other pressure sensors A...

Page 188: ...tool in order to verify that the repair eliminates the fault and then permanently install the new sensor If the fuel rail is replaced use the electronic service tool to per form the Rail Pressure Valv...

Page 189: ...the J2 connector D Turn the keyswitch to the ON position Wait at least 10 sec onds for activation of the diagnostic codes Note Diagnostic codes for all of the engine sensors will be ac tive with the...

Page 190: ...rature while this diagnostic code is active The default value is 10 C 14 F at engine start gradually increasing to 90 C 194 F as the engine is running The engine will be derated 110 4 Engine Coolant T...

Page 191: ...r the fuel temperature is 40 C 104 F 3242 0 Particulate Trap Intake Gas Temperature High most severe 3 The ECM detects that the temperature signal from the Diesel Particulate Filter DPF inlet temperat...

Page 192: ...ing procedures for the diagnostic codes of each temperature sensor are identical The temperature sensors have two terminals The signal voltage from each sensor is supplied to the appropriate terminal...

Page 193: ...anifold temperature sensor Refer to the appropriate Electrical Schematic Illustration 53 g03625277 Typical view of the P2 pin locations for the temperature sensors 23 Engine fuel temperature sensor gr...

Page 194: ...tive D Check if any of the diagnostic codes listed in Table 93 are active or recently logged Codes Result A 3 diagnostic code is active Proceed to Test Step 2 Result A 4 diagnostic code is active Proc...

Page 195: ...e Suspect Sensor Connector A Turn the keyswitch to the OFF position B Disconnect the sensor connector of the suspect sensor with the active 4 diagnostic code C Turn the keyswitch to the ON position D...

Page 196: ...following background information is related to this procedure The ECM supplies regulated 5 VDC to the following sensors on the J2 connector a 3509 2 diagnostic code applies to the 5 VDC supply for the...

Page 197: ...ectrical Schematic Illustration 56 g03775432 Typical example of the 5 VDC supply circuit supplied by the J1 connector A 3510 2 diagnostic code applies to the 5 VDC supply in this illustration Not all...

Page 198: ...VDC supply 13 Secondary camshaft speed timing sensor 5 VDC supply 24 NRS valve position sensor ground 25 Intake manifold air pressure sensor 26 Fuel rail pressure sensor ground 27 Exhaust gas pressur...

Page 199: ...the failed sensor Verify that the repair resolved the problem Result The suspect sensor supply active code remains ac tive after all sensors on the sensor supply circuit have been checked Repair The f...

Page 200: ...t condition in the output from the ECM to the solenoid in the wastegate regulator for at least 0 2 seconds The battery voltage is at least 10 VDC The diagnostic code will be logged The following backg...

Page 201: ...c Illustration 61 g02351359 View of the pin locations on the P2 connector for the solenoid valves 4 Wastegate regulator return 15 Fuel metering valve supply 60 Fuel metering valve return Illustration...

Page 202: ...position B Connect the electronic service tool to the diagnostic connector C Turn the keyswitch to the ON position D Monitor the electronic service tool for active diagnostic co des and or logged dia...

Page 203: ...Turn the keyswitch to the ON position E Use the electronic service tool to check for an active 1076 diagnostic code Wait at least 30 seconds for activation of the diagnostic codes F Turn the keyswitc...

Page 204: ...diagnostic code is still active with the valve disconnected Proceed to Test Step 9 9 Create an Open Circuit at the ECM A Turn the keyswitch to the OFF position B Disconnect the P2 connector from the E...

Page 205: ...e limp home speed the engine will decelerate to the limp home speed If the engine speed is lower than the limp home speed the engine speed will remain at the current speed The engine will remain at th...

Page 206: ...c for the application Illustration 64 g02292314 View of the P1 pin locations for the analog throttle position sensors 16 5 V supply throttle 1 17 5 V supply throttle 2 38 Throttle 1 ground 39 Throttle...

Page 207: ...onic service tool to check for diagnostic codes Diagnostic codes Result One or more of the diagnostic codes that are listed in Table 99 is active or recently logged Proceed to Test Step 5 Result There...

Page 208: ...e at the Sensor A Turn the keyswitch to the OFF position B Disconnect the connector for the suspect throttle position sensor C Turn the keyswitch to the ON position D Measure the voltage between the 5...

Page 209: ...t in the wiring for the sensor Check all wiring between the suspect sensor and the ECM Re fer to the Electrical Schematic for the application Replace the faulty wiring Use the electronic service tool...

Page 210: ...des and then verify that the repair eliminates the fault Result The measured resistance is less than 5 Ohms Contact the DSN If the procedure did not correct the fault contact the DSN i06019830 Speed T...

Page 211: ...gnal is also used to determine the engine speed The secondary speed timing sensor is located in the front cover The secondary speed timing sensor generates a signal that is related to the camshaft pos...

Page 212: ...648462 View of the pin locations for the speed timing sensors on the P2 connector 13 Secondary speed timing sensor 5 V supply 14 Secondary speed timing sensor signal 28 Secondary speed timing sensor g...

Page 213: ...ed timing sensor Illustration 68 g02648517 Typical example of the secondary speed timing sensor 1 Secondary speed timing sensor ground 2 Secondary speed timing sensor signal 3 Secondary speed timing s...

Page 214: ...ine will start then run the engine D Use the electronic service tool in order to monitor active di agnostic codes or recently logged diagnostic codes Diagnostic codes Result Diagnostic code 190 8 is a...

Page 215: ...peed timing sensor E Turn the keyswitch to the OFF position F Reconnect the connector for the secondary speed timing sensor 4 9 V to 5 1 V Result The measured voltage is not within the expected range...

Page 216: ...roceed to Test Step 10 8 Inspect the Sensors A Ensure that the speed timing sensors are correctly seated in the cylinder block and the front cover and that the retaining bolts are tightened to the cor...

Page 217: ...rder to clear all logged diag nostic codes and then verify that the repair has eliminated the fault Result No faults found Contact the Dealer Solution Network DSN 10 Check if a Replacement ECM Elimina...

Page 218: ...ollowing conditions The signal voltage from the throttle switch is above 4 8 VDC for at least 0 5 seconds The battery voltage is at least 10 VDC The warning lamp will come on 2880 4 Engine Operator Pr...

Page 219: ...are shown Refer to the Electrical Schematic for the application Illustration 71 g02723018 Typical view of the pin locations on the P1 connector for the throttle switch 55 Throttle switch signal 77 Thr...

Page 220: ...tive Proceed to Test Step 5 3 Create an Open Circuit at the Switch A Turn the keyswitch to the OFF position B Disconnect the throttle switch C Turn the keyswitch to the ON position D Use the electroni...

Page 221: ...ween the throttle switch and the ECM Refer to the Electrical Schematic for the application Replace the faulty wiring Use the electronic service tool to clear all logged diag nostic codes and verify th...

Page 222: ...il pressure switch While the engine is running and oil pressure is detected the switch will be open When no oil pressure is detected the switch will be closed Table 106 Oil Pressure Switch States and...

Page 223: ...ck for Active or Recently Logged Diagnostic Codes A Turn the keyswitch to the OFF position B Connect the electronic service tool to the diagnostic connector C Turn the keyswitch to the ON position Do...

Page 224: ...witch to the OFF position Diagnostic codes Result A 100 2 diagnostic code is active with the P2 connector disconnected The fault is in the wiring between the oil pressure switch and the P2 ECM connect...

Page 225: ...twork DSN B If the DSN recommends the use of a replacement ECM in stall a replacement ECM Refer to Troubleshooting Replac ing the ECM C Use the electronic service tool to recheck the system for ac tiv...

Page 226: ...running key on Open Normal condition Running Open Normal Condition no air filter restric tion detected Not running Closed 107 2 Running Closed 107 15 or 107 16 Table 110 Diagnostic Summary for a Norma...

Page 227: ...or of pinch points Proceed to Test Step 2 2 Check for Active or Recently Logged Diagnostic Codes A Turn the keyswitch to the OFF position B Connect the electronic service tool to the diagnostic conne...

Page 228: ...stance measurements is less than 1 k Ohm The fault is in the wiring between the air filter restriction switch and the P1 ECM connector Check all wiring between the switch and the ECM Refer to the Elec...

Page 229: ...r for the switch Disconnect the P1 connector from the ECM C Use a suitable multimeter to measure the resistance be tween P1 87 and the signal terminal on the harness connector for the switch Less than...

Page 230: ...least 0 5 seconds The intake throttle valve will move to the default position while the diagnostic code is active The default position is 0 percent Use this procedure in order to troubleshoot the pos...

Page 231: ...Intake throttle valve position sensor 5 VDC supply 9 NRS valve position sensor 5 VDC supply 24 NRS valve position sensor ground 34 Intake throttle valve return 35 NRS valve return 37 Intake throttle...

Page 232: ...iminates the fault Result All connectors pins and sockets are correctly con nected and or inserted and the harness is free of corrosion of abrasion or of pinch points Proceed to Test Step 3 3 Measure...

Page 233: ...de is active with the P2 connec tor disconnected The fault is in the wiring for the suspect sensor between the suspect valve connector and the P2 connector Check all wiring between the suspect valve a...

Page 234: ...pair eliminates the fault Result The XX 3 diagnostic code is still active with the jumper wire installed Proceed to Test Step 9 9 Check if a Replacement ECM Eliminates the Fault A Contact the Dealer S...

Page 235: ...connectors are shown Refer to the Electrical Schematic for the application Illustration 79 g02734203 Typical view of the pin location on the P1 connector for the WIF sensor 30 WIF sensor signal UENR0...

Page 236: ...de is not active at this time If the WIF sensor is not operating correctly proceed to Test Step 5 3 Disconnect the WIF Sensor A Turn the keyswitch to the OFF position B Disconnect the WIF sensor from...

Page 237: ...The measured voltage is at least 11 V Proceed to Test Step 7 7 Create a Short Circuit at the WIF Sensor Connector A Turn the keyswitch to the OFF position B Disconnect the WIF sensor from the harness...

Page 238: ...e required level Click Change for an individual cylinder in order to switch off that cylinder manually This test can be used to identify faults by listening to the sound of the engine as a cylinder is...

Page 239: ...en the oxygen sensor is replaced DPF Differential Pressure Sensor Replacement Use this reset when the DPF differential pressure sensor is replaced DPF Replacement Reset Use this reset when a new DPF i...

Page 240: ...tly installed Repair or replace the connectors as necessary Result The connectors are OK Proceed to Test Step 3 3 Communication Adapter and or Cables A Check that the firmware and driver files are the...

Page 241: ...pply to the ECM is OK Contact the Dealer Solution Network DSN i06043620 ECM Software Install Flash Programming A method of loading a flash file into the Electronic Control Module ECM The electronic se...

Page 242: ...correct flash file for your engine i06022850 ECM Replace NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life The engine is equipped with an El...

Page 243: ...reen click on OK 13 Check for logged diagnostic codes i06022909 Electrical Connectors Inspect Most electrical faults are caused by poor connections The following procedure will assist in detecting fau...

Page 244: ...red Ensure that all of the seals are correctly installed Ensure that the con nectors have been reattached If corrosion is evident on the pins sockets or the connector use only denatured alcohol to rem...

Page 245: ...ector and verify that the terminals are correctly located in the connector Use the electronic service tool in order to clear all logged di agnostic codes and then verify that the repair eliminates the...

Page 246: ...rminals are OK Proceed to Test Step 6 6 Check the Locking Mechanism of the Connectors A Ensure that the connectors lock correctly After locking the con nectors ensure that the two halves cannot be pul...

Page 247: ...ector code that was recorded in Test Step 1 8 Click on the OK button The injector code is loaded into the ECM 9 Repeat the procedure for each cylinder as required Exchanging Electronic Unit Injectors...

Page 248: ...s Interrupted 48 Recommended Actions 48 Diesel Particulate Filter Collects Excessive Soot 49 Probable Causes 50 Recommended Actions 50 Diesel Particulate Filter Has Differential Pressure Problem 51 Pr...

Page 249: ...8 Recommended Actions 98 G General Information 5 Application Interface 5 Clean Emissions Module CEM 5 Electronic Control System 5 Fault Detection and Reporting 5 Important Safety Information 5 Overvie...

Page 250: ...gnostic Codes 238 Override Parameters 238 Solenoid Valve Test 199 Speed Control Test 205 Speed Timing Test 210 Switch Circuits Test Air Filter Restriction Switch 225 Switch Circuits Test Engine Oil Pr...

Page 251: ...This document has been printed from SPI2 NOT FOR RESALE...

Page 252: ...2015 Perkins Engines Company Limited All Rights Reserved This document has been printed from SPI2 NOT FOR RESALE...

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