Page 1 SENR9982 November 2005 Troubleshooting 1106D Industrial Engine PJ (Engine )
Page 2 Obtain the complete and most current information before you s t ar t any jo b . Perkins dea le rs or Perkins distributor hav e t he m os t c ur r en t i nfo rm ati on a va il abl e.
Page 3: Table Of Contents
SENR9982 Table of Contents Table of Contents Intermittent Engine Shutdown ....... 66 Intermittent Low Power or Power Cutout ....67 Low Engine Oil Pressure ........69 Low Power/Poor or No Response to Throttle ..70 Troubleshooting Section Mechanical Noise (Knock) in Engine ....72 Noise Coming from Cylinder .........
Page 4 SENR9982 Table of Contents CID 0100 FMI 03 Engine Oil Pressure open/short to CID 1797 FMI 03 Fuel Rail Pressure Sensor +batt ..............90 open/short to +batt ..........104 CID 0100 FMI 04 Engine Oil Pressure short to CID 1797 FMI 04 Fuel Rail Pressure Sensor short to ground ..............
Page 5: Troubleshooting Section
SENR9982 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i02414573 System Overview System Operation g01178531 Illustration 1 (1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor (2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped) (3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
Page 6 SENR9982 Troubleshooting Section • The 1106D engine was designed for electronic Throttle position sensor control. The engine has an Electronic Control Module (ECM), a fuel rail pump and electronic unit injectors. At start-up, the ECM determines the top center All of these items are electronically controlled. There position of the number 1 cylinder from the secondary are also a number of engine sensors.
Page 7: Glossary
Coolant Temperature Sensor – The coolant on a computer system that is available only to temperature sensor detects the engine coolant Perkins distributors. Since factory passwords contain temperature for all normal operating conditions and alphabetic characters, only an electronic service for engine monitoring.
Page 8 DT, DT Connector, or Deutsch DT – This is a type 0 – The data is valid but the data is above the normal of connector that is used on Perkins engines. The operational range. connectors are manufactured by Deutsch.
Page 9 SENR9982 Troubleshooting Section 8 – There is an abnormal frequency, an abnormal Fuel Ratio Control (FRC) – The FRC is a limit that pulse width, or an abnormal time period. is based on the control of the ratio of the fuel to air. The FRC is used for purposes of emission control.
Page 10 SENR9982 Troubleshooting Section Intake Manifold Air Temperature Sensor – The Power Cycled – Power cycled happens when power intake manifold air temperature sensor detects the to the ECM is cycled: ON, OFF, and ON. Power air temperature in the intake manifold. The ECM cycled refers to the action of cycling the keyswitch monitors the air temperature and other data in the from any position to the OFF position, and to the...
Page 11: Electronic Service Tools
These parameters can be changed by use of the electronic service tool. The tattletale logs the number of changes that have been made to the parameter. Perkins electronic service tools are designed to help The tattletale is stored in the ECM. the service technician: Theft Deterrent –...
Page 12 Perkins 28170107 Bypass Harness As Electronic Service Tool software. 2900A038 Harness As Perkins Electronic Service Tool The Perkins Electronic Service Tool can display the following information: • Programmable parameter settings • Active diagnostic codes and logged diagnostic codes •...
Page 13: Indicator Lamps
SENR9982 Troubleshooting Section Connecting the Electronic Service Tool 4. Place the keyswitch in the ON position. If the Electronic Service Tool and the communication and the Communication Adapter II adapter do not communicate with the Electronic Control Module (ECM), refer to the diagnostic procedure Troubleshooting, “Electronic Service Tool Will Not Communicate With ECM”.
Page 14 SENR9982 Troubleshooting Section On – The lamp will be on when the shutdown level has been reached. The “Shutdown” lamp will also be on. Wait to Start Lamp Lamp check – The lamp will come on for 2 seconds. The lamp will then go off unless “Wait to Start” is active.
Page 15 SENR9982 Troubleshooting Section Operation of the Indicator Lamps Table 4 Warning Shutdown Lamp State Description of the Indication Engine State Lamp Lamp (Alert (Action Lamp) Lamp) Lamp Check When the keyswitch is switched on, the lamps The keyswitch is on but the come on for a period of 2 seconds and the lamps engine has not yet been will then go off.
Page 16 SENR9982 Troubleshooting Section The sequence for the flash code is started by moving the keyswitch to “Off” and then moving the keyswitch to “On” twice within a period of three seconds. After a delay of 2 seconds, the “Shutdown” lamp will flash once for a period of half a second.
Page 17: Replacing The Ecm
SENR9982 Troubleshooting Section i02414637 NOTICE Replacing the ECM If the Personality Module and engine application are not matched, engine damage may result. Perform the following procedure in order to replace NOTICE the ECM. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- 1.
Page 18: Self-Diagnostics
SENR9982 Troubleshooting Section 8. If necessary, use the electronic service tool to Logged Code – Every generated code is stored in clear the rating interlock in the Personality Module. the permanent memory of the ECM. The codes are To clear the rating interlock, enter the factory logged.
Page 19 SENR9982 Troubleshooting Section g01178874 Illustration 5 (1) Coolant Temperature Sensor (4) Fuel Rail Pressure Sensor (7) Primary Speed/Timing Sensor (2) Intake Manifold Temperature Sensor (5) Electronic Control Module (ECM) (8) Secondary Speed/Timing Sensor (3) Intake Manifold Pressure Sensor (6) Oil Pressure Sensor (9) Solenoid for the Fuel Rail Pump Note: If equipped, the wastegate regulator is installed on the right side of the engine.
Page 20 SENR9982 Troubleshooting Section g01178875 Illustration 6...
Page 21 SENR9982 Troubleshooting Section Table 5 Connector Function Machine Harness to ECM Connector (64 Pin Connector) Engine Harness to ECM Connector (64 Pin Connector) P532 Fuel Rail Pump Solenoid Connector (2 Pin Connector) P402 Secondary Speed/Timing Sensor (2 Pin Connector) P401 Primary Speed/Timing Sensor (2 Pin Connector) P201 Engine Oil Pressure Sensor (3 Pin Connector)
Page 22: Engine Wiring Information
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.
Page 23 SENR9982 Troubleshooting Section Table 6 Color Codes for the Harness Wire Color Code Color Color Code Color Black Blue Brown Purple Gray Orange White Yellow Pink Green For example, a wire identification of F730-OR on the schematic would signify an orange wire with the circuit number F730.
Page 24 SENR9982 Troubleshooting Section Schematic Diagrams g01213981 Illustration 8 Schematic Diagram for the Engine Harness...
Page 25 SENR9982 Troubleshooting Section g01213983 Illustration 9 Schematic Diagram for a Typical Application...
Page 26: Ecm Harness Connector Terminals
SENR9982 Troubleshooting Section i02414687 ECM Harness Connector Terminals The Electronic Control Module (ECM) uses connectors that have 64 terminals to interface to the wiring harness. g01201559 Illustration 11 Removal of Terminal Position Assurance Components 1. Remove the connector from the ECM. Refer to g01170706 Illustration 10 Disassembly and Assembly, “Electronic Control...
Page 27 SENR9982 Troubleshooting Section 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 28170085 must be used.
Page 28: Programming Parameters
SENR9982 Troubleshooting Section Programming Parameters 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 i02415216 ECM is not in “Test ECM Mode”, the ECM can never Programming Parameters be used as a test ECM.
Page 29 SENR9982 Troubleshooting Section The ECM can store a maximum of two snapshots that are triggered by a diagnostic code. Two snapshots can be triggered manually. The snapshots are stored in a circular buffer. The newest snapshot will replace the oldest snapshot. The ECM stores the snapshots in memory.
Page 30: Factory Passwords
Operating the engine with a flash file not designed for that engine will damage the engine. Be sure the flash file is correct for your engine. Note: Factory passwords are provided only to Perkins dealers. Factory passwords are required to perform each of the following functions: •...
Page 31: Flash Programming
SENR9982 Troubleshooting Section Note: If you do not have the part number for the flash Table 8 file, use “PTMI” on the Perkins Internet. Factory Passwords Worksheet Dealer Code Note: You must have the engine serial number in order to search for the flash file’s part number.
Page 32: Injector Trim File
“Switch 1” is connected to J1:39 Mode Switch 1. “Switch 2” is connected to J1:46 Mode Switch 2. • Select “Service Software Files” on the Perkins The other contact on both switches is connected to Internet. J1:35 Switch Return.
Page 33: Throttle Setup
Electronic Control Module (ECM) for a given combination of switch positions. There is a maximum The 1106D engine can have a digital throttle that of four ratings in a flash file. uses a Pulse Width Modulated (PWM) signal, an...
Page 34 SENR9982 Troubleshooting Section Idle Validation Minimum Off • PWM throttle Threshold • Multi-position switch This is the minimum throttle percentage that will be • Communications port throttle detected by the ECM when the idle validation switch is OFF. If the ECM detects a throttle percentage below this value with the idle validation switch in the ON position, a fault code will be generated.
Page 35: Multiposition Switch Setup
SENR9982 Troubleshooting Section Lower Dead Zone Table 20 Range Default This is a throttle range above the initial lower position 0 to 100 percent 0 percent limit before the engine will increase in rpm. Table 25 Lower Position Limit Range Default This is the minimum throttle percentage that will 0 to 100 percent...
Page 36 SENR9982 Troubleshooting Section Input 4, Input 3, Input 2, Input 1 The number of these non-programmable parameters that are visible depends on the value that is programmed into the “Number of Switch Inputs” parameter. “Open” signifies that the switch is in the OFF position.
Page 37: Customer Specified Parameters
SENR9982 Troubleshooting Section Customer Specified Table 33 Parameters Minimum Maximum Default 1900 rpm 2900 rpm 2420 rpm i02415248 ECM Identification Parameter Customer Specified Parameters Equipment ID “Equipment ID” is the identification of the equipment that is assigned by the customer. The “Equipment Customer specified parameters allow the engine to ID”...
Page 38 SENR9982 Troubleshooting Section Table 36 Table 40 Minimum Maximum Default Value Default 0 rpm 3000 rpm 0 rpm Disabled Enabled Enabled Throttle Lock Increment Speed Ramp Limp Home Desired Engine Speed Rate The “Limp Home Desired Engine Speed” is the The “Throttle Lock Increment Speed Ramp Rate”...
Page 39 SENR9982 Troubleshooting Section Table 43 Value Default Disabled Disabled Enabled Air Filter Restriction Switch Installation Status An “Air Filter Restriction Switch” is an optional switch input. Programming the “Air Filter Restriction Switch Installation Status” parameter to “Enabled” notifies the ECM that an input from the air filter restriction switch is present on pin J1:47.
Page 40: Customer Specified Parameters Table
SENR9982 Troubleshooting Section i02415250 Customer Specified Parameters Table Table 47 Customer Specified Parameters ECM Parameter Possible Values Default Value Engine Rating Parameter “Rating Number” 1 to 4 Low/High Idle Parameters “Low Idle Speed” 700 to 1200 rpm 800 rpm “High Idle Speed” 1900 to 2900 rpm 2420 rpm ECM Identification Parameter...
Page 41: Customer Specified Parameters Worksheet
SENR9982 Troubleshooting Section i02415254 Customer Specified Parameters Worksheet Table 48 Customer Specified Parameters Worksheet Engine Rating Parameter “Rating Numbers” Low/High Idle Parameters “Low Idle Speed” “High Idle Speed” ECM Identifications Parameters “Equipment ID” PTO and Throttle Lock Parameters “Throttle Lock Feature Installation Status” “PTO Engine Speed Setting”...
Page 42: System Configuration Parameters
SENR9982 Troubleshooting Section System Configuration • The engine will not run. Parameters • Diagnostic code 0253-02 Personality Module mismatch will be active. i02415260 Note: The flash programming of a new rating System Configuration interlock replaces the old rating interlock. Parameters This code does not need to be programmed when the replacement ECM is for the same engine rating.
Page 43: Troubleshooting Without A Diagnostic Code
SENR9982 Troubleshooting Section Troubleshooting without a Alternator Bearings Diagnostic Code 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 be replaced if the bearings are worn. Refer to i02344739 Disassembly and Assembly, “Alternator - Remove”...
Page 44: Battery
SENR9982 Troubleshooting Section • Throttle signal from the throttle position sensor i02344743 Battery • Air intake and exhaust system • Valve lash Note: This is not an electronic system problem. • Turbocharger Probable Causes • Fuel supply • Low compression (cylinder pressure) •...
Page 45 SENR9982 Troubleshooting Section 3. If the engine has a throttle switch refer to 6. Ensure that the wastegate on the turbocharger is Troubleshooting, “Throttle Switch Circuit - Test”. adjusted correctly. Refer to Testing and Adjusting, “Wastegate - Inspect”. If the wastegate actuator 4.
Page 46: Coolant In Engine Oil
SENR9982 Troubleshooting Section Individual Malfunctioning Cylinders 1. With the engine speed at a fast idle, use the Contact with high pressure fuel may cause fluid electronic service tool to isolate one cylinder at penetration and burn hazards. High pressure fu- a time.
Page 47: Coolant Temperature Is Too High
SENR9982 Troubleshooting Section Assembly after Repair • Cylinder head gasket • Cylinder head 1. Install the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install”. • Cylinder block 2. Remove the oil filter element. Install a new engine oil filter element.
Page 48: Ecm Will Not Accept Factory Passwords
SENR9982 Troubleshooting Section Radiator Cap and/or Pressure Relief 3. If necessary, replace the coolant pump. Refer to Disassembly and Assembly, “Water Pump - Valve Remove” and Disassembly and Assembly, “Water Pump - Install”. 1. Pressure test the cooling system. Refer to Testing and Adjusting, “Cooling System”...
Page 49: Ecm Will Not Communicate With Other Systems Or Display Modules
• Wiring to other control modules Electrical Connectors 3. Troubleshoot the Perkins Data Link for possible problems. Refer to Troubleshooting, “Data Link Check for correct installation of the P1/J1 and P2/J2 Circuit - Test”.
Page 50: Engine Cranks But Will Not Start
Missing components “Flash Programming”. • Damaged components Perkins Data Link • Damaged electrical cables or loose electrical Troubleshoot the Perkins Data Link for possible cables faults. Refer to Troubleshooting, “Data Link Circuit - Test”. • Oil leaks • Fuel leaks •...
Page 51 SENR9982 Troubleshooting Section Fuel Supply 2. Use a suitable hand tool in order to rotate the crankshaft. If the crankshaft does not rotate freely, check the engine for the following problems: 1. Visually check the fuel tank for fuel. The fuel gauge may be faulty.
Page 52: Engine Has Early Wear
SENR9982 Troubleshooting Section 4. Ensure that the repairs have eliminated the faults. Make sure that the engine is maintained at the correct maintenance intervals. Refer to the Operation 5. If the repair does not eliminate the fault refer to and Maintenance Manual, “Maintenance Interval “Electronic Unit Injectors”.
Page 53: Engine Misfires, Runs Rough Or Is Unstable
SENR9982 Troubleshooting Section 3. If the engine has a 10 position throttle switch refer i02413824 to Troubleshooting, “Throttle Switch Circuit - Test”. Engine Misfires, Runs Rough or Is Unstable 4. If the repairs do not eliminate the fault proceed to “Air Intake and Exhaust System”.
Page 54 Note: The fuel rail pump that is installed by the factory on the 1106D engine is a nonserviceable 2. Rectify any faults. item. If any mechanical fault or any electrical fault occurs within the fuel rail pump then the fuel rail 3.
Page 55: Engine Oil In Cooling System
SENR9982 Troubleshooting Section 2. Check the mating face of the cylinder head for i02413836 faults and signs of leakage. If a fault is found, Engine Oil in Cooling System replace the cylinder head. If signs of leakage are found, determine the cause of the leakage. Refer to Testing and Adjusting, “Cylinder Head - Inspect”...
Page 56: Engine Stalls At Low Rpm
SENR9982 Troubleshooting Section Use the electronic service tool to check the setup of If there are no faults with the accessory equipment, the throttle. refer to “Power Mode Control (If Equipped)”. Throttle Switch Power Mode Control (If Equipped) If a fault with the throttle switch is suspected, refer to 1.
Page 57: Engine Vibration
SENR9982 Troubleshooting Section 2. If the fault is not eliminated, reinstall the original 2. Make all necessary repairs. Ensure that the electronic unit injectors. Refer to Disassembly and repairs have eliminated the fault. If the vibration Assembly, “Electronic Unit Injectors - Remove” is still present proceed to “Low Compression and Disassembly and Assembly, “Electronic Unit (Cylinder Pressure)”.
Page 58: Engine Will Not Crank
SENR9982 Troubleshooting Section Electronic Unit Injectors 3. If the 1639-09 diagnostic code is active the machine security system is armed. Deactivate 1. With the engine speed at a fast idle, use the the machine security system and try to start the electronic service tool to isolate one cylinder at engine.
Page 59: Excessive Black Smoke
SENR9982 Troubleshooting Section • 2. Attempt to rotate the crankshaft through 360 Check for the correct engine serial number degrees in both direction. If the crankshaft rotates • correctly but fluid is expelled from the hole for the Check for the correct arrangement number glow plug, investigate the cause of the fluid in the •...
Page 60 SENR9982 Troubleshooting Section Individual Malfunctioning Cylinder 4. Check that the turbine housing for the turbocharger is free of dirt, debris and damage. 1. With the engine speed at a fast idle, use the 5. Check that the turbine blades rotate freely in the electronic service tool to isolate one cylinder at turbocharger.
Page 61: Excessive Engine Oil Consumption
SENR9982 Troubleshooting Section 3. Check the air intake and the exhaust system for i02414536 the following defects: Excessive Engine Oil Consumption • Blockages • Restrictions • Damage to the air intake and exhaust lines and Probable Causes hoses • Oil leaks 4.
Page 62: Excessive Fuel Consumption
SENR9982 Troubleshooting Section Quality of Oil • Damaged cylinder head 3. Perform all necessary repairs. 1. The nominal viscosity of the lubricating oil that is used in the engine will affect the rate of fuel 4. Ensure that the repairs have eliminated the faults. consumption.
Page 63: Excessive Valve Lash
SENR9982 Troubleshooting Section Operation of the engine for long periods at idle 4. If the turbocharger is suspected as being faulty, speed will cause a deterioration of the internal replace the turbocharger. Refer to Disassembly components of the engine. A deterioration of the and Assembly, “Turbocharger - Remove”...
Page 64: Excessive White Smoke
SENR9982 Troubleshooting Section Recommended Actions • Low coolant temperature • Glow plugs Lubrication • Fuel quality 1. Remove the valve mechanism covers. Refer to Disassembly and Assembly, “Valve Mechanism • Valve lash Cover - Remove and Install” for the correct procedure.
Page 65: Intake Air Temperature Is Too High
Measure the intake manifold pressure while the on any cylinder that is operating below normal engine is operating under load. For specific data, performance. refer to the Perkins Technical Marketing Information for the engine. 2. Rectify any faults. Intake Air Restriction 1.
Page 66: Intermittent Engine Shutdown
SENR9982 Troubleshooting Section Reduced Flow of Intake Air through the 2. Replace the air filters or remove the obstruction from the air intake. Air Charge Cooler High Altitude 1. Check for contamination in the air pipe that connects the turbocharger to the air charge cooler. Make sure that the settings for the engine are correct for the altitude.
Page 67: Intermittent Low Power Or Power Cutout
SENR9982 Troubleshooting Section Electrical Connectors 6. Check that the low pressure fuel lines are tight and secured properly. 1. Check for correct installation of ECM connectors at the following locations: 7. Check the fuel filters. • P2 ECM connector 8. Check the diesel fuel for contamination. Refer to Testing and Adjusting, “Fuel Quality - Test”.
Page 68 SENR9982 Troubleshooting Section 2. Repair the electrical connectors or replace the 6. Refer to Troubleshooting, “Analog Throttle electrical connectors. Position Circuit - Test” or Troubleshooting, “Digital Throttle Position Circuit - Test”. 3. Ensure that all the connector seals are in place and that the connectors have been correctly 7.
Page 69: Low Engine Oil Pressure
SENR9982 Troubleshooting Section • 1785-04 Intake Manifold Pressure Sensor 3. If the fault is still apparent, refer to “Engine Oil voltage low Pressure Gauge”. If either of these diagnostic codes are logged, Engine Oil Pressure Gauge proceed to Troubleshooting, “Engine Pressure Sensor Open or Short Circuit - Test”.
Page 70: Low Power/Poor Or No Response To Throttle
SENR9982 Troubleshooting Section Recommended Actions Engine Oil Pump 1. Inspect the components of the engine oil pump for NOTICE excessive wear. Repair the oil pump or replace Do not crank the engine continuously for more than the oil pump, if necessary. Refer to Disassembly 30 seconds.
Page 71 SENR9982 Troubleshooting Section 6. If the engine speed is erratic refer to 6. Ensure that the wastegate on the turbocharger is Troubleshooting, “Analog Throttle Position Sensor adjusted correctly. Refer to Testing and Adjusting, Circuit - Test” or Troubleshooting, “Digital Throttle “Wastegate - Inspect”.
Page 72: Mechanical Noise (Knock) In Engine
SENR9982 Troubleshooting Section Possible causes of low compression are shown 3. Install a new electronic unit injector. Refer to in the following list: Disassembly and Assembly, “Electronic Unit Injector - Install”. • Loose glow plugs 4. Repeat the test in 1. If the fault is still apparent, •...
Page 73: Noise Coming From Cylinder
SENR9982 Troubleshooting Section Connecting Rod and Main Bearings Electronic Unit Injectors Inspect the connecting rod and main bearings. 1. With the engine speed at a fast idle, use the Also, inspect the bearing surfaces (journals) on the electronic service tool to isolate one cylinder at crankshaft.
Page 74: Troubleshooting With A Diagnostic Code
SENR9982 Troubleshooting Section Troubleshooting with a Diagnostic Code i02411250 Diagnostic Code Cross Reference Table 49 3rd Party Device Flash CDL Code Description J1939 Code Code No Diagnostic Code Detected 0001-02 Cylinder #1 Injector Data Incorrect 651-2 0001-05 Cylinder #1 Injector open circuit 651-5 0001-06 Cylinder #1 Injector short...
Page 75 SENR9982 Troubleshooting Section (Table 49, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 0091-03 Accelerator pedal - voltage above normal 91-03 0091-04 Accelerator pedal - voltage below normal 91-04 0091-08 Throttle Position signal abnormal 91-08 0100-03 Engine Oil Pressure open/short to +batt 100-03 0100-04 100-04...
Page 76: No Diagnostic Codes Detected
SENR9982 Troubleshooting Section (Table 49, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 1797-04 Fuel Rail Pressure Sensor short to ground 157-04 1834-02 Ignition Keyswitch loss of signal 158-02 2246-06 Glow plug Start Aid Relay Current High 676-06 Event Codes E172-1...
Page 77: Cid 0001 Fmi 05 Cylinder #1 Injector Open Circuit
SENR9982 Troubleshooting Section System Response: An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring If equipped, the warning light will come on. An active that is unique to the electronic unit injector will prevent diagnostic code will be generated.
Page 78: Cid 0001 Fmi 07 Cylinder #1 Injector Not Responding
SENR9982 Troubleshooting Section An electrical fault can prevent the electronic unit i02411597 injector from operating. A short circuit in the wiring or CID 0002 FMI 02 Cylinder #2 the ECM that is unique to one electronic unit injector Injector Data Incorrect will prevent that individual electronic unit injector from operating.
Page 79: Cid 0002 Fmi 06 Cylinder #2 Injector Short
SENR9982 Troubleshooting Section • The Electronic Control Module (ECM) detects the Battery voltage above 9 volts for 2 seconds following condition: System Response: • A low current condition (open circuit) for each of five consecutive attempts to operate If equipped, the warning light will come on. The ECM will log the diagnostic code.
Page 80: Cid 0003 Fmi 02 Cylinder #3 Injector Data Incorrect
SENR9982 Troubleshooting Section Troubleshooting: Results: • Replace the suspect electronic unit injector. Refer OK – STOP. to Disassembly and Assembly, “Electronic Unit Injector - Remove” and Disassembly and Assembly, i02412172 “Electronic Unit Injector - Install”. CID 0003 FMI 05 Cylinder #3 Use the electronic service tool to perform the fuel Injector open circuit system verification test.
Page 81: Cid 0003 Fmi 06 Cylinder #3 Injector Short
SENR9982 Troubleshooting Section i02412173 i02412174 CID 0003 FMI 06 Cylinder #3 CID 0003 FMI 07 Cylinder #3 Injector short Injector Not Responding Conditions Which Generate This Code: Conditions Which Generate This Code: This diagnostic code is designed to indicate a short The electronic unit injector is no longer capable of circuit (high current) in either the solenoid or the delivering the correct amount of fuel.
Page 82: Cid 0004 Fmi 05 Cylinder #4 Injector Open Circuit
SENR9982 Troubleshooting Section • No 0262 diagnostic codes are active. Troubleshooting: • Diagnostic code 0190-08 is not active. When an injector cutout test is performed, a faulty electronic unit injector will indicate a low reading in • No 0110 diagnostic codes are active. comparison with the other electronic unit injectors.
Page 83: Cid 0004 Fmi 07 Cylinder #4 Injector Not Responding
SENR9982 Troubleshooting Section Troubleshooting: Results: • When an injector cutout test is performed, a faulty OK – STOP. electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors. i02412179 CID 0005 FMI 02 Cylinder #5 An electrical fault can prevent the electronic unit injector from operating.
Page 84: Cid 0005 Fmi 05 Cylinder #5 Injector Open Circuit
SENR9982 Troubleshooting Section i02412180 i02412181 CID 0005 FMI 05 Cylinder #5 CID 0005 FMI 06 Cylinder #5 Injector open circuit Injector short Conditions Which Generate This Code: Conditions Which Generate This Code: This diagnostic code is designed to indicate an open This diagnostic code is designed to indicate a short circuit (low current) in either the solenoid or the wiring circuit (high current) in either the solenoid or the...
Page 85: Cid 0005 Fmi 07 Cylinder #5 Injector Not Responding
SENR9982 Troubleshooting Section • No 0262 diagnostic codes are active. i02412182 CID 0005 FMI 07 Cylinder #5 • Diagnostic code 0190-08 is not active. Injector Not Responding • No 0110 diagnostic codes are active. System Response: Conditions Which Generate This Code: If equipped, the warning light will come on.
Page 86: Cid 0006 Fmi 06 Cylinder #6 Injector Short
SENR9982 Troubleshooting Section An electrical fault can prevent the electronic unit An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring injector from operating. A short circuit in the wiring or that is unique to the electronic unit injector will prevent the ECM that is unique to one electronic unit injector that individual electronic unit injector from operating.
Page 87: Cid 0041 Fmi 03 8 Volt Dc Supply Short To +Batt
SENR9982 Troubleshooting Section • The ECM has been powered for more than three i02412194 seconds. CID 0041 FMI 03 8 Volt DC Supply short to +batt • Diagnostic code 0168-01 is not active. System Response: The ECM will log the diagnostic code and the ECM Conditions Which Generate This Code: will trigger a snapshot.
Page 88: Cid 0091 Fmi 03 Accelerator Pedal - Voltage Above Normal
SENR9982 Troubleshooting Section • The reduction of speed is determined by the current A signal voltage for the throttle position is above speed of the engine. normal. • When a fault is detected and the engine is above the The power supply for the throttle sensor is within predetermined safe speed, the engine will reduce the expected range.
Page 89: Cid 0091 Fmi 04 Accelerator Pedal - Voltage Below Normal
SENR9982 Troubleshooting Section Test Step 2. i02412210 CID 0091 FMI 04 Accelerator Perform the following diagnostic procedure: “Digital pedal - voltage below normal Throttle Position Sensor Circuit - Test” Results: • OK – STOP. Conditions Which Generate This Code: The Electronic Control Module (ECM) detects all of i02412215 the following conditions: CID 0091 FMI 08 Throttle...
Page 90: Cid 0100 Fmi 03 Engine Oil Pressure Open/Short To +Batt
SENR9982 Troubleshooting Section Results: Results: • • OK – STOP. OK – STOP. i02411238 i02411239 CID 0100 FMI 03 Engine Oil CID 0100 FMI 04 Engine Oil Pressure open/short to +batt Pressure short to ground Conditions Which Generate This Code: Conditions Which Generate This Code: The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the...
Page 91: Cid 0100 Fmi 10 Engine Oil Pressure Sensor Abnormal Rate Of Change
SENR9982 Troubleshooting Section i02411241 i02411242 CID 0100 FMI 10 Engine Oil CID 0110 FMI 03 Engine Pressure Sensor abnormal Coolant Temperature rate of change open/short to +batt Conditions Which Generate This Code: Conditions Which Generate This Code: The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the following conditions: following conditions:...
Page 92: Cid 0168 Fmi 00 System Voltage High
SENR9982 Troubleshooting Section • The signal voltage from the engine coolant System Response: temperature sensor is less than 0.2 VDC for more than eight seconds. The ECM will log the diagnostic code. If equipped, the warning lamp may come on. •...
Page 93: Cid 0168 Fmi 02 System Voltage Intermittent/Erratic
SENR9982 Troubleshooting Section Troubleshooting: i02412239 CID 0172 FMI 03 Intake Perform the following diagnostic procedure: “Ignition Manifold Air Temp open/short Keyswitch Circuit and Battery Supply Circuit - Test” to +batt Results: • OK – STOP. Conditions Which Generate This Code: i02412227 The Electronic Control Module (ECM) detects the CID 0168 FMI 02 System...
Page 94: Cid 0172 Fmi 04 Intake Manifold Air Temp Short To Ground
SENR9982 Troubleshooting Section i02412242 i02412247 CID 0172 FMI 04 Intake CID 0190 FMI 08 Engine Speed Manifold Air Temp short to signal abnormal ground Conditions Which Generate This Code: Conditions Which Generate This Code: The Electronic Control Module (ECM) detects the following conditions: The Electronic Control Module (ECM) detects the following conditions:...
Page 95: Cid 0247 Fmi 12 J1939 Data Link Malfunction
SENR9982 Troubleshooting Section • Another controller has stopped transmitting a i02412959 J1939 speed request (TSC1) incorrectly. CID 0253 FMI 02 Personality Module mismatch System Response: Some system functions may not operate correctly. Troubleshooting: Conditions Which Generate This Code: Perform the following diagnostic procedure: “CAN The Electronic Control Module (ECM) detects Data Link Circuit - Test”...
Page 96: Cid 0262 Fmi 03 5 Volt Sensor Dc Power Supply Short To +Batt
SENR9982 Troubleshooting Section System Response: Results: • Default timing is used. This code will not be logged. OK – STOP. If equipped, the warning light will be on when this code is active. i02412962 CID 0262 FMI 04 5 Volt Sensor Possible Performance Effect: DC Power Supply short to The engine may not run smoothly when this code...
Page 97: Cid 0268 Fmi 02 Check Programmable Parameters
SENR9982 Troubleshooting Section i02412963 i02412964 CID 0268 FMI 02 Check CID 0342 FMI 08 Secondary Programmable Parameters Engine Speed signal abnormal Conditions Which Generate This Code: Conditions Which Generate This Code: The Electronic Control Module (ECM) detects one or The Electronic Control Module (ECM) detects the more of the following conditions: following conditions: •...
Page 98: Cid 0526 Fmi 06 Turbo Wastegate Drive Current High
SENR9982 Troubleshooting Section • A low current condition in the output from the ECM Possible Performance Effect: to the solenoid for the wastegate regulator The engine will be derated while this diagnostic code • No 0168 diagnostic codes are active. is active.
Page 99: Cid 0774 Fmi 02 Secondary Throttle Position Sensor Data Erratic
SENR9982 Troubleshooting Section • The engine produces excessive black smoke. The throttle switch will also be ignored by the ECM until the keyswitch has been turned to the OFF • The engine has low power. position and then back to the ON position. •...
Page 100: Cid 0774 Fmi 04 Sec Throttle Position Sensor Short To Ground
SENR9982 Troubleshooting Section If the engine is equipped with a digital throttle position Troubleshooting: sensor, proceed to “Test Step 2”. Monitor the configuration screen on the electronic service tool in order to determine the type of throttle Test Step 1. position sensor that is used on the engine.
Page 101: Cid 1639 Fmi 09 Machine Security System Module Not Communicating On Link
SENR9982 Troubleshooting Section • • The frequency of the signal from the digital (PWM) The ECM detects a loss of communications with sensor is greater than 1050 Hz for more than 1 the Machine Security System (MSS). second. System Response: System Response: The ECM will log the diagnostic code.
Page 102: Cid 1779 Fmi 05 Fuel Rail Pressure Valve 1 Solenoid Open Circuit
SENR9982 Troubleshooting Section Possible Performance Effect: i02412976 CID 1779 FMI 05 Fuel Rail An electrical fault may prevent the provision of Pressure Valve 1 Solenoid pressure to the fuel rail. This may result in the loss of fuel injection. If the solenoid for the fuel rail pump open circuit fails, it is likely that fuel will not be pumped into the fuel rail.
Page 103: Cid 1785 Fmi 04 Intake Manifold Pressure Sensor Voltage Low
SENR9982 Troubleshooting Section Possible Performance Effect: Possible Performance Effect: • • The engine will be derated. The engine will be derated. Troubleshooting: Troubleshooting: This diagnostic code can be caused by an open This code can be caused by a short to ground or a circuit or a short to another power source.
Page 104: Cid 1797 Fmi 03 Fuel Rail Pressure Sensor Open/Short To +Batt
SENR9982 Troubleshooting Section System Response: System Response: If equipped, the warning light will be on. The ECM If equipped, the warning lamp will be on. The ECM will log the diagnostic code. The ECM will trigger will log the diagnostic code. The ECM will trigger a snapshot.
Page 105: Cid 1834 Fmi 02 Ignition Key Switch Loss Of Signal
SENR9982 Troubleshooting Section Possible Performance Effect: i02413816 CID 2246 FMI 06 Glow Plug The engine will be derated. Start Aid Relay Current High Troubleshooting: This diagnostic code can be caused by a loss of the 5 V supply or a short to ground on the signal wire. Conditions Which Generate This Code: Perform the following diagnostic procedure: “Engine The Electronic Control Module (ECM) has detected a...
Page 106: Troubleshooting With An Event Code
SENR9982 Troubleshooting Section Troubleshooting with an Results: Event Code • OK – STOP. i02411184 i02411237 E232 High Fuel/Water Event Codes Separator Water Level The ECM can log events. Events refer to engine operating conditions such as low oil pressure or high Conditions Which Generate This Code: coolant temperature.
Page 107: E360 Low Engine Oil Pressure
SENR9982 Troubleshooting Section i02411185 E360 Low Engine Oil Pressure Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a problem with the engine’s oil pressure. The ECM detects the following problems: • The engine has been running for more than ten seconds.
Page 108: E361 High Engine Coolant Temperature
SENR9982 Troubleshooting Section i02411186 E361 High Engine Coolant Temperature Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a problem with the engine’s coolant temperature. The ECM detects the following problems: • The engine has been running for more than three minutes.
Page 109: E362 Engine Overspeed
The event may be viewed by using a display module • Event code 1797-04 Fuel Rail Pressure Sensor or by using the Perkins Electronic Service Tool (EST). open/short to ground is not active. The ECM will reset the engine speed when the engine •...
Page 110: E398 Low Fuel Rail Pressure
SENR9982 Troubleshooting Section Results: i02411194 E398 Low Fuel Rail Pressure • OK – STOP. i02411196 Conditions Which Generate This Code: E539 High Intake Manifold Air Temperature The Electronic Control Module (ECM) detects a problem with low fuel rail pressure. The ECM detects the following problem: •...
Page 111: E2143 Low Engine Coolant Level
SENR9982 Troubleshooting Section Table 53 Intake Manifold Air Temperature Trip Level Table E539-1 E539-2 Engine Model Turbocharged Aftercooled 82 °C (179 °F) 86 °C (186 °F) Engines (TA) Table 54 i02411198 E2143 Low Engine Coolant Derate Map for Turbocharged Aftercooled Engines (TA) Level Intake Manifold Air...
Page 112: Diagnostic Functional Tests
SENR9982 Troubleshooting Section Diagnostic Functional • A suspect sensor Tests • A suspect ECM i02421074 5 Volt Sensor Supply Circuit - Test System Operation Description: Use this procedure to troubleshoot the system when one of the following diagnostic codes is active or easily repeated: •...
Page 113 SENR9982 Troubleshooting Section Table 55 P2 Pin Connections Sensor Pin Function Fuel Rail Pressure Intake Manifold Oil Pressure sensor Sensor Pressure Sensor Volts (5 V) Common Signal Table 56 P1 OEM Connector Sensor Pin Function Throttle 1 Throttle 2 +5 V Ground Signal g01188143...
Page 114 SENR9982 Troubleshooting Section g01173224 Illustration 16 Typical example of the fuel rail pressure sensor (1) Voltage supply (Vs) (2) Ground (GND) (3) Signal (SIG) g01173225 Illustration 17 Typical example of the intake manifold pressure sensor (1) Voltage Supply (Vs) (2) Ground (GND) (3) Signal (SIG) g01173226 Illustration 18...
Page 115 SENR9982 Troubleshooting Section g01173227 Illustration 19 Typical example of the P2 pressure sensor pin locations (38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5V)) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor Sensor Sensor (39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (5V) Fuel Rail Pressure (40) Ground (GND) Fuel Rail Pressure Sensor...
Page 116 Verify that the repair eliminates the fault. • STOP. Test Step 2. Check for Active Diagnostic • Pressure sensors Codes • Throttle pedal A. Connect the Perkins Electronic Service Tool (EST) to the diagnostic connector.
Page 117 B. Turn the keyswitch to the ON position. Repair: Reconnect all of the sensors except the suspect sensor. C. Use the Perkins EST in order to monitor the diagnostic codes. Check and record any active Proceed to Test Step 4.
Page 118 J1:55 if a throttle sensor is installed. If the throttle • OK – The 5 volt diagnostic code is not active. sensors are OK then the fault is intermittent. Repair: Use the Perkins EST in order to clear all Refer to Troubleshooting, “Electrical Connectors diagnostic codes. - Inspect”.
Page 119: Analog Throttle Position Sensor Circuit - Test
SENR9982 Troubleshooting Section Test Step 7. Measure the +5 Volt Supply Repair: If the fault is intermittent, refer to to the Sensor Troubleshooting, “Electrical Connectors - Inspect”. STOP. A. Turn the keyswitch to the ON position. • Not OK – The voltage is not within the range. Note: All the pressure sensors and the analog throttle demand sensors (if equipped) should be disconnected.
Page 120 SAE J1939 (CAN), or from the PTO controls. Use the Perkins Electronic Service Tool (EST) in order to check the input status. Use the Perkins EST in order to check the input status. Table 57 P1 Pin Connections...
Page 121 A. Turn the keyswitch to the ON position. C. Refer to Troubleshooting, “Electrical Connectors B. Use the Perkins EST to check for diagnostic - Inspect”. codes. D. Perform a 45 N (10 lb) pull test on each of the...
Page 122 OK – The supply voltage is reaching the sensor. A. Check the status of the throttle selection switch (if Proceed to Test Step 6. equipped). Use the Perkins EST in order to check the status of the throttle selection switch. •...
Page 123 SENR9982 Troubleshooting Section E. Observe the voltage while the engine speed Repair: Check for the correct supply voltage at control is moved from the minimum to the the ECM. If the voltage is correct, then the ECM maximum position. is suspect. Expected Result: 1.
Page 124: Can Data Link Circuit - Test
SENR9982 Troubleshooting Section • Not OK – The sensor is faulty. Repair: Replace the sensor. Verify that the repair has eliminated the fault. STOP. i02430608 CAN Data Link Circuit - Test System Operation Description: g01170753 Illustration 25 Throttle block assembly Use this procedure under the following (1) Mounting screw holes circumstances:...
Page 125 SENR9982 Troubleshooting Section g01209010 Illustration 26 Typical example of the schematic for the CAN data link g01209013 Illustration 27 Typical view of the P1 OEM connector pin locations (20) CAN- (21) CAN+ (22) CAN Shield Test Step 1. Inspect Electrical Connectors B.
Page 126 SENR9982 Troubleshooting Section • C. Perform a 45 N (10 lb) pull test on each of the Result 3 – The resistance is between 110 and 130 wires that are associated with the CAN data link. Ohms. One of the terminating resistors may have Refer to Illustration 27.
Page 127: Data Link Circuit - Test
This message will indicate that the version of the to diagnose other devices on the data link. software that is in the Perkins EST is not the same version of the software that is in the ECM. Install the Verify that the repair eliminates the fault.
Page 128 Illustration 28 Schematic of the diagnostic connector and the Perkins data link connector g01208535 Illustration 29 Typical view of the P2 pin locations for the diagnostic and Perkins data link connectors (20) Data link (PDL) - (21) Data link (PDL) +...
Page 129 SENR9982 Troubleshooting Section g01208545 Illustration 30 Typical view of the P1 pin locations for the diagnostic and Perkins data link connectors (23) Data link (PDL) + (24) Data link (PDL) - Test Step 1. Inspect Electrical Connectors Results: and Wiring.
Page 130 SENR9982 Troubleshooting Section Results: Repair: Fabricate a jumper wire in order to connect pin “A” of the diagnostic connector to +battery and • OK – The communications adapter is currently pin “B” to the -battery. receiving the correct voltage. Proceed to Test Step Proceed to Test Step 2.
Page 131 Perkins EST cables. Ensure that the set of Perkins EST cables are a complete Note: Refer to Troubleshooting, “Electronic Service set. Tools” for details of the bypass harness.
Page 132 SENR9982 Troubleshooting Section g01215173 Illustration 32 Schematic of the bypass harness connector...
Page 133: Digital Throttle Position Sensor Circuit - Test
(20) J1939 (CAN) - A. Connect the battery wires from the bypass 5. If the fault is resolved with the test ECM, harness of the Perkins EST to a different battery reconnect the suspect ECM. that is not on the engine.
Page 134 PTO mode. The ECM is in PTO mode if the “PTO ON/OFF Switch” is ON. This can be checked with Perkins Electronic Service Tool (EST). Refer to Troubleshooting, “PTO Switch Circuit - Test” for testing if the PTO is being used.
Page 135 ECM connector that are associated Test Step 2. Check for Active Diagnostic with the digital throttle position sensor: Codes • P1:33 A. Connect Perkins EST to the data link connector. • P1:43 B. Turn the keyswitch to the ON position. • P1:53 C.
Page 136 A. Access the active diagnostic code screen on • Result 1 – Proceed to Test Step 3. Perkins EST. Ensure that one of the following diagnostic code is active before proceeding: • Result 2 – Proceed to Test Step 5.
Page 137 Result 1 – The digital throttle position sensor is Temporarily install another digital throttle position operating correctly. Continue troubleshooting until sensor. Use the Perkins EST in order to check for the original condition is resolved. STOP. an active +8 V diagnostic code. Replace the digital •...
Page 138 Expected Result: If the battery voltage is correct, temporarily connect a test ECM. Use Perkins EST to verify that the The duty cycle is between 10 and 22 percent with the active diagnostic code is resolved. If the fault is...
Page 139 SENR9982 Troubleshooting Section G. Turn the keyswitch to the OFF position. H. Remove the P1 OEM connector from the ECM. I. Install the pin P1:53. J. Connect the P1 OEM connector to the ECM. Expected Result: The duty cycle is between 10 and 22 percent with the throttle pedal assembly in the low idle position, and the duty cycle is between 75 and 90 percent with the throttle pedal assembly in the high idle position.
Page 140: Ecm Memory - Test
A 253-02 code is active F. Check the duty cycle of the digital throttle position sensor on Perkins EST while the digital throttle Repair: Obtain the engine serial number. Use SIS pedal assembly is being moved over the full range.
Page 141: Electrical Connectors - Inspect
SENR9982 Troubleshooting Section Test Step 1. Check Connectors for i02411206 Moisture and Corrosion Electrical Connectors - Inspect System Operation Description: Most electrical faults are caused by poor connections. The following procedure will assist in detecting faults with connectors and with wiring. If a fault is found correct the condition and verify that the fault is resolved.
Page 142 SENR9982 Troubleshooting Section B. Ensure that the sealing plugs are in place. If any If moisture or corrosion is evident in the connector, of the plugs are missing, replace the plug. Ensure the source of the moisture entry must be found that the plugs are inserted correctly into the and the source of the moisture entry must be connector.
Page 143 SENR9982 Troubleshooting Section Test Step 2. Check the Wires for Damage Repair: Repair the terminals and/or replace the to the Insulation terminals, as required. A. Carefully inspect each wire for signs of abrasion, Verify that the repair eliminates the fault. of nicks, and of cuts.
Page 144 SENR9982 Troubleshooting Section Repair: Use the CH11155 Crimp Tool to replace B. Verify that the latch tab of the connector is the terminal. Replace damaged connectors, as correctly latched. Also verify that the latch tab of required. the connector returns to the locked position. Verify that the repair eliminates the fault.
Page 145: Engine Pressure Sensor Open Or Short Circuit - Test
• 1785-04 Intake Manifold Pressure Sensor voltage A. Select the “Wiggle Test” from the diagnostic tests on the Perkins Electronic Service Tool (EST). • B. Choose the appropriate group of parameters to 1785-10 Intake Manifold Pressure Signal abnormal monitor.
Page 146 SENR9982 Troubleshooting Section g01188154 Illustration 45 Typical example of the schematic for the sensors...
Page 147 SENR9982 Troubleshooting Section The troubleshooting procedures for the diagnostic codes of each pressure sensor are identical. The pressure sensors are active sensors. The pressure sensor has three terminals. Active sensors require supply voltage from the ECM. The ECM connector P2/J2 supplies +5 volts to terminal 1 of each sensor.
Page 148 F. Check the harness for abrasions and for pinch sensor connectors: points from the sensors back to the ECM. • P201 Engine Oil Pressure Sensor G. Use the Perkins EST to perform a “Wiggle Test”. The “Wiggle Test” will identify intermittent • P228 Fuel Rail Pressure Sensor connections.
Page 149 An open circuit diagnostic code for the disconnected sensor is now active. Verify that the repair eliminates the fault. Results: Use the Perkins EST in order to clear all logged • diagnostic codes. OK – A short circuit diagnostic code was active before disconnecting the sensor.
Page 150 4. Use the Perkins EST to verify that the repair E. Use the Perkins EST to check for a short circuit eliminated the fault. diagnostic code. The new sensor should be connected to the harness at this time.
Page 151 H. Turn the keyswitch to the ON position. Repair: Perform the following repair: I. Use the Perkins EST to monitor the “Active Diagnostic Code” screen for either the open circuit 1. Temporarily connect a test ECM. diagnostic code for the sensor or the short circuit diagnostic code for the sensor.
Page 152: Engine Speed/Timing Sensor Circuit - Test
SENR9982 Troubleshooting Section The loss of signal to the primary sensor and/or the i02411208 secondary sensor will result in one of the following Engine Speed/Timing Sensor faults: Circuit - Test • The loss of signal from the secondary speed/timing sensor during start-up will prevent the engine from starting.
Page 153: Table 58
SENR9982 Troubleshooting Section Table 58 P2/J2 Pin Connections Function Sensor Pin Crankshaft Primary Sensor Camshaft Secondary Sensor +8 Volt Supply Signal g01206953 Illustration 50 The schematic for the speed/timing sensors g01188474 Illustration 51 Typical view of the speed/timing sensor pin locations (10) Speed/ Timing sensor supply (8v) (52) Crankshaft speed timing sensor signal (53) Pump/Cam speed sensor signal (Sig)
Page 154 SENR9982 Troubleshooting Section g01188476 Illustration 52 Typical view of the sensor locations (1) Primary crankshaft speed timing sensor (2) Secondary speed/timing sensor g01188477 g01212569 Illustration 53 Illustration 54 (1) Primary speed timing sensor (crankshaft) (2) Secondary speed/timing sensor (camshaft)
Page 155 • Not OK D. Use the Perkins EST in order to monitor active Repair: Repair the faulty connectors or the diagnostic codes or recently logged diagnostic harness and/or replace the faulty connectors or the codes.
Page 156 SENR9982 Troubleshooting Section • 190-08 Engine Speed signal abnormal B. Disconnect the P2 connector. Disconnect the connector for the primary speed/timing sensor. • 342-08 Secondary Engine Speed signal abnormal Disconnect the connector for the secondary speed/timing sensor. Results: C. Check the resistance between P2:52 to the •...
Page 157 The resistance should be more than E. Start the engine. 20,000 Ohms. F. Use the Perkins EST in order to monitor the D. Check the resistance between P2:10 to each diagnostic codes. of the other pins on P2. Check the resistance between P2:10 to the ground and battery+ G.
Page 158: Engine Temperature Sensor Open Or Short Circuit - Test
Coolant temperature sensor E. Start the engine. • Intake manifold air temperature sensor F. Use the Perkins EST in order to monitor the Use this procedure to troubleshoot the system when diagnostic codes. one of the following diagnostic codes is an active diagnostic code or a recently logged diagnostic code G.
Page 159 B. Turn the keyswitch to the ON position. Note: Wait at least 30 seconds for activation of the diagnostic codes. C. Use the Perkins EST in order to verify if any of the following diagnostic codes are active or recently logged: •...
Page 160 ECM. A. Turn the keyswitch to the ON position. F. Use the Perkins EST to perform a “Wiggle Test”. The “Wiggle Test” will identify intermittent Note: Wait at least 30 seconds for activation of the connections.
Page 161 (terminal 2). D. Access the “Active Diagnostic Code” screen of Note: Wait at least 30 seconds for activation of the the Perkins EST. Check for an active open circuit short circuit diagnostic code. diagnostic code. Expected Result:...
Page 162 ECM to the sensor connector with for the sensors. Reassemble the P2 connector to sockets on both ends. the ECM. Use the Perkins EST in order to check the diagnostic codes. Wait at least 30 seconds for activation of the short circuit diagnostic code.
Page 163: Fuel Rail Pump Solenoid - Test
I. Use the Perkins EST in order to monitor the “Active Diagnostic Code” screen for either the The fuel rail pump solenoid is used to control the open circuit diagnostic code for the sensor or the output from the fuel rail pump.
Page 164 SENR9982 Troubleshooting Section g01207610 Illustration 59 Typical schematic of the circuit for the fuel rail pump solenoid g01194219 Illustration 60 Typical view of the P2 ECM pin locations for the electrical power supply circuit (25) Fuel rail pump solenoid PWM signal (26) Fuel rail pump solenoid return Test Step 1.
Page 165 Not OK – There is an open circuit. Proceed to Test Step 4. C. Use the Perkins EST to verify if any of the following Test Step 4. Check the Fuel Rail Pump diagnostic codes are active or recently logged: Solenoid for an Open Circuit •...
Page 166 C. Turn the keyswitch to the ON position. Reconnect the P2 to the ECM. Check the screw for the ECM connector for the correct torque of D. Use the Perkins EST in order to perform the fuel 5.0 N·m (44 lb in). rail pump solenoid test.
Page 167: Idle Validation Switch Circuit - Test
IVS thresholds when a new throttle assembly connector. is installed. D. Turn the keyswitch to the ON position. E. Use the Perkins EST in order to monitor the status screen. F. Use the Perkins EST in order to perform the fuel rail pump solenoid test.
Page 168 SENR9982 Troubleshooting Section g01207665 Illustration 61 Schematic of the idle validation switch (IVS) circuit...
Page 169: Sensor Ground
• OK – The IVS state changes from CLOSED (ON) to OPEN (OFF). Proceed to Test Step 2. C. Use the Perkins EST in order to check the current “Throttle Configuration”. • Not OK – The IVS does not operate.
Page 170 Validation Min OFF Threshold” and the “Idle Test Step 4. Check the Location of the Validation Max ON Threshold” parameters. Use Fault the Perkins EST in order to view the parameters of the IVS switch. STOP. A. Disconnect the IVS harness connector. •...
Page 171 A. Turn the keyswitch to the OFF position. connector pin on the P1 connector and P1:35. B. Disconnect the IVS. F. Use the Perkins EST in order to monitor the IVS status. Note the status of the IVS. C. Set the throttle to low idle.
Page 172 “YES” if an IVS is installed. Make a note of the “Idle Validation Min OFF The Perkins EST can be used to reset the “Idle Threshold” parameters that are displayed in the Validation Min OFF Threshold” and the “Idle “Throttle Configuration”...
Page 173: Ignition Keyswitch Circuit And Battery Supply Circuit - Test
Ignition Keyswitch Circuit and connector is independent of the keyswitch. Therefore, you will be able to power up the Perkins Electronic Battery Supply Circuit - Test Service Tool (EST), but you may not be able to communicate with the engine ECM.
Page 174: Illustration 63
SENR9982 Troubleshooting Section g01193794 Illustration 63 Schematic for the ignition keyswitch and battery supply circuit g01193796 Illustration 64 Typical rear view of the pin locations for the ignition keyswitch and battery supply circuit (1) Battery ground (GND) (9) Battery ground (GND) (2) Battery ground (GND) (10) Battery ground (GND) (3) Battery ground (GND)
Page 175 P1: 1, 2, 3, 9, 10 (−Battery) Expected Result: • P1:40 (keyswitch) One of the following diagnostic codes is active or C. Use the Perkins EST to perform a “Wiggle Test”. logged: Special attention must be paid to the following • connections: 168-00 System Voltage High •...
Page 176 SENR9982 Troubleshooting Section F. Measure the voltage between P1:16 (keyswitch) For intermittent faults such as intermittent and P1:10 (-Battery). shutdowns that could be caused by the application wiring, temporarily bypassing the application wiring G. Measure the voltage between P1:40 (keyswitch) may be an effective means of determining the root and P1:3 (-Battery).
Page 177 SENR9982 Troubleshooting Section Test Step 5. Bypass the Application Harness Batteries give off flammable fumes which can ex- plode. To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery. NOTICE Do Not connect the bypass harness to the battery un- til all of the in-line fuses have been removed from the...
Page 178: Indicator Lamp Circuit - Test
Use this procedure under the following circumstances: E. Connect the Perkins EST to the diagnostic • The lamps are not receiving battery voltage. connector of the bypass harness and verify that communication can be established.
Page 179 SENR9982 Troubleshooting Section g01212865 Illustration 66 Typical schematic of the indicator lamp circuit g01176466 Illustration 67 Typical example of the P1 OEM connector pin locations (1) Ground (GND) (7) Battery (+) (59) Warning lamp (2) Ground (GND) (8) Battery (+) (60) Stop lamp (3) Ground (GND) (15) Battery (+)
Page 180 A. Turn the keyswitch to the ON position. D. Check the screw for the P1 OEM connector for the B. Use the Perkins EST to select the “override” correct torque of 5.0 N·m (44 lb in). function in order to switch individual lamps ON and OFF.
Page 181: Injector Data Incorrect - Test
Use this procedure to identify the F. Turn the keyswitch to the ON position. Use the cause of the diagnostic code. Use this procedure to Perkins EST to select the override function in repair the system. order to switch individual lamps ON and OFF.
Page 182 Not OK – No related diagnostic codes are logged. STOP. Test Step 2. Check the Faulty Cylinder Numbers A. Use the Perkins EST in order to make a note of g01208822 Illustration 68 the logged diagnostic codes. Typical example of the electronic unit injector B.
Page 183: Injector Solenoid Circuit - Test
5-05 Cylinder #5 Injector open circuit Refer to Troubleshooting, “Replacing the ECM”. • 5-06 Cylinder #5 Injector short B. Use the Perkins EST in order to perform the “Fuel • System Verification - Test.”. Verify that the test 6-05 Cylinder #6 Injector open circuit eliminates the fault.
Page 184 SENR9982 Troubleshooting Section g01208822 Illustration 69 Typical example of the fuel injector...
Page 185 SENR9982 Troubleshooting Section g01212858 Illustration 70 Schematic for the injector solenoid circuit...
Page 186 SENR9982 Troubleshooting Section g01190721 Illustration 71 Typical example of the fuel injector harness connector g01190722 Illustration 72 Typical example of the cylinder head mounted connector g01171366 Illustration 73 P2 pin connections (6) Injector Cylinder (Number 6 Return) (34) Injector Cylinder (Number 2 Return) (59) Injector Cylinder (Number 3) (7) Injector Cylinder (Number 5 Return) (35) Injector Cylinder (Number 1 Return)
Page 187 A. Connect the Perkins EST to the diagnostic connector. E. Select the start button at the bottom of the screen for the cylinder cutout test on the Perkins EST. B. Turn the keyswitch to the ON position. F. Select the “6 Cylinder Cutout Test”.
Page 188 Expected Result: Expected Result: All cylinders indicate “OK”. All cylinders indicate “OK” on the Perkins EST. Results: Results: • OK – There is not an electronic fault with the •...
Page 189 Repair: Repair the injector harness or replace the injector harness under the valve cover. Expected Result: Verify that the repair eliminates the fault. Perkins EST displays “Short” for the cylinder with the jumper wire. STOP. • Results: Not OK – The injector may be faulty.
Page 190 SENR9982 Troubleshooting Section Note: Shorting a shared supply will affect the status Expected Result: of three injectors. Ignore the status of the other injectors that are on the shared shared supply. All cylinders indicate “Open”. Results: Results: • • OK – The ECM is OK. OK –...
Page 191 SENR9982 Troubleshooting Section • Not OK – There may be a fault with the ECM. Repair the injector harness or replace the injector harness under the valve cover. Repair: Temporarily connect a test ECM. Verify that the repair eliminates the fault. Perform the “Injector Solenoid Test”.
Page 192: Mode Selection Circuit - Test
SENR9982 Troubleshooting Section Perform the “Injector Solenoid Test” in order to verify that the repair eliminates the fault. STOP. i02411232 Mode Selection Circuit - Test System Operation Description: Use this procedure under the following circumstances: • Diagnostic code 1743-02 has been generated. •...
Page 193 SENR9982 Troubleshooting Section g01210839 Illustration 74 Typical schematic for the mode selector switches g01174989 Illustration 75 Typical view of the pin locations for the P1 OEM connector (35) Mode switch return (GND) (39) Mode switch 1 (46) Mode switch 2 Test Step 1.
Page 194 C. Turn the keyswitch to the ON position. Test Step 4. Measure the Resistance of D. Monitor the status screen on the Perkins EST. the Wire Harness at the ECM Cycle the mode switch to the ON position and to the OFF position.
Page 195: Pto Switch Circuit - Test
The PTO switches are listed below: OEM connector, the mode switch indication on the • Perkins EST will be in the OFF position. The switch P1 OEM connector: 52 PTO Control ON or P1 will indicate an open condition. •...
Page 196 SENR9982 Troubleshooting Section g01206861 Illustration 76 Schematic for the PTO switches g01187525 Illustration 77 Typical view of the PTO switch pin locationson the P1 OEM connector (35) Switch Ground (GND) (50) PTO mode - raise/resume (52) PTO mode - ON/OFF (49) PTO mode - disengage (51) PTO mode - set/lower Test Step 1.
Page 197 C. Turn the keyswitch to the ON position. A. Use the Perkins EST in order to observe the switch status while the PTO mode disengage D. Observe the status of the PTO mode switch on the switches are operated OFF and ON.
Page 198 C. Turn the keyswitch to the ON position. Verify that the repair has eliminated the fault. STOP. D. Monitor the status screen on the Perkins EST while the jumper wire is being disconnected and Test Step 6. Test the Engine ECM reconnected.
Page 199: Starting Aid (Glow Plug) Relay Circuit - Test
Starting aids may be used if the engine has previously been started. The “Wait to Start” lamp will not be active in these conditions. Perkins Electronic Service Tool (EST) Test Aid The Perkins Electronic Service Tool (EST) includes the test “Glow Plug Override Test”. The “Glow Plug Override Test”...
Page 200 SENR9982 Troubleshooting Section g01209584 Illustration 78 Typical schematic for the starting aid switch...
Page 201 Note: The engine has not been started at this Test Step. F. Check that the fuses are not blown. C. Use the Perkins EST to select the “Glow Plug Expected Result: Override Test” in order to turn on the power for the glow plugs.
Page 202 • If an intermittent fault is suspected, use the Verify that the repair has eliminated the fault. Perkins EST to perform a “Wiggle Test” in order to locate intermittent connections. If the fault still exists, proceed to Test Step 4.
Page 203: Throttle Switch Circuit - Test
E. Use the Perkins EST in order to perform a “Glow Plug Override Test”. Voltage at the throttle inputs to the ECM should be 13.8 ±...
Page 204 SENR9982 Troubleshooting Section g01206862 Illustration 80 Schematic for the circuit for the throttle switch g01193299 Illustration 81 Typical view of the pin locations for the throttle switch on the P1 OEM connector (35) Switch return (50) Throttle position switch 2 (52) Throttle position switch 4 (49) Throttle position switch 1 (51) Throttle position switch 3...
Page 205 Harness Position” on the Perkins Electronic Service Tool (EST) A. Turn the keyswitch to the OFF position. A. Connect Perkins Electronic Service Tool (EST) at B. Disconnect P1 OEM connector and throttle switch the diagnostic connector. connector P503/J503. B. Turn the keyswitch to the ON position.
Page 206: Wastegate Solenoid - Test
Test Step 5. Check Resistance through K. Observe the status of the suspect throttle input on the Harness Perkins EST. L. Turn the keyswitch to the OFF position. A. Use a jumper wire to short P503:1 to the terminal of the suspect throttle input at throttle switch connector J503.
Page 207 SENR9982 Troubleshooting Section Use this procedure if another procedure has directed you here. Use this procedure if any of the following diagnostic codes are active: • 526-05 Turbo Wastegate Drive current low • 526-06 Turbo Wastegate Drive current high • 526-07 Turbo Wastegate Drive not responding properly Some engine models will have a turbocharger with...
Page 208 SENR9982 Troubleshooting Section g01190759 Illustration 82 Schematic for the wastegate g01172792 Illustration 83 Wastegate connector (1) Ground (GND) (2) Signal (SIG)
Page 209 A. Turn the keyswitch to the OFF position. wires that are associated with the wastegate solenoid. B. Connect the Perkins Electronic Service Tool (EST) C. Check the screw for the ECM connector for the to the data link connector. correct torque of 5.0 N·m (44 lb in).
Page 210 “Turbo Wastegate Solenoid Test”. Wait at least and ensure that the connectors are completely 30 seconds in order for the result to be displayed. coupled. E. Check for active diagnostic codes on the Perkins Verify that the repair eliminates the fault. EST. STOP.
Page 211 Not OK – There is still an open circuit diagnostic the Perkins EST. Activate the “Turbo Wastegate code. Solenoid Output” on the Perkins EST. Wait at least 30 seconds for activation of the diagnostic codes. Repair: Perform the following procedure: D.
Page 212: Index
SENR9982 Index Section Index Numerics CID 0005 FMI 02 Cylinder #5 Injector Data Incorrect............... 83 5 Volt Sensor Supply Circuit - Test ....... 112 CID 0005 FMI 05 Cylinder #5 Injector open circuit ..............84 CID 0005 FMI 06 Cylinder #5 Injector short ..84 CID 0005 FMI 07 Cylinder #5 Injector Not Responding............
Page 213 CID 1834 FMI 02 Ignition Key Switch loss of Optional Service Tools ........12 signal ..............105 Perkins Electronic Service Tool......12 CID 2246 FMI 06 Glow Plug Start Aid Relay Current Required Service Tools ........12 High ..............105 Electronic Troubleshooting ........
Page 214 SENR9982 Index Section Engine Wiring Information ........22 Harness Wire Identification ........ 22 Schematic Diagrams.......... 24 Low Engine Oil Pressure ........69 Event Codes ............106 Probable Causes ..........69 Excessive Black Smoke ........59 Recommended Actions........69 Probable Causes ..........59 Low Power/Poor or No Response to Throttle ..
Page 215 SENR9982 Index Section System Configuration Parameters......42 ECM Software Release Date ......42 Engine Serial Number........42 Full Load Setting ..........42 Full Torque Setting ..........42 Rating Interlock ..........42 System Overview............. 5 Diagnostic Codes..........7 Passwords ............7 Programmable Parameters........

Perkins 1106D Troubleshooting Manual

Quick Links

Troubleshooting

Related Manuals for Perkins 1106D

Summary of Contents for Perkins 1106D

Table of Contents