Perkins M190C Troubleshooting Manual
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Perkins M190C Troubleshooting Manual

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KENR9126
September 2010

Troubleshooting

M190C, M216C, M250C and M300C
Marine Engine
PJ (Engine)

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Summary of Contents for Perkins M190C

  • Page 1: Troubleshooting

    KENR9126 September 2010 Troubleshooting M190C, M216C, M250C and M300C Marine Engine PJ (Engine)

  • Page 2: Important Safety Information

    These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

  • Page 3: Table Of Contents

    KENR9126 Table of Contents Table of Contents Mechanical Noise (Knock) in Engine ....65 Noise Coming from Cylinder ......... 65 Poor Acceleration or Response ......66 Transmission Oil Pressure Is High ......67 Troubleshooting Section Transmission Oil Temperature Is High ....68 Electronic Troubleshooting Troubleshooting with a Diagnostic Code System Overview ............
  • Page 4 KENR9126 Table of Contents Indicator Lamp Circuit - Test ....... 183 CID 0262 FMI 04 ..........93 Injector Data Incorrect - Test ....... 186 CID 0268 FMI 02 ..........93 CID 0342 FMI 08 ..........94 Injector Solenoid Circuit - Test ......188 CID 0342 FMI 11 ...........

  • Page 5: Troubleshooting Section

    KENR9126 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i04009195 System Overview...
  • Page 6 KENR9126 Troubleshooting Section System Operation g02190173 Illustration 1 Typical example...
  • Page 7 KENR9126 Troubleshooting Section (1) Electronic unit injectors (18) Secondary throttle (35) Fuel supply pressure sensor (if (2) Electronic Control Module (ECM) (19) Warning lamp equipped) (3) Electronic Service Tool (EST) (20) Diagnostic lamp (36) Transmission oil pressure sensor (if (4) Diagnostic connector (21) Maintenance lamp equipped) (5) SMMS relay...

  • Page 8: Glossary

    The Rated Fuel Limit enables the engine power and on a computer system that is available only to torque outputs to conform to the power and torque Perkins distributors. Since factory passwords contain curves of a specific engine model. alphabetic characters, only an electronic service tool may change System Configuration Parameters.
  • Page 9 DT, DT Connector, or Deutsch DT – This is a type CAN Data Link (see also J1939 CAN Data Link) – of connector that is used on Perkins engines. The The CAN Data Link is a serial communications port that is used for communication with other connectors are manufactured by Deutsch.
  • Page 10 KENR9126 Troubleshooting Section 3 – The voltage is above normal or the voltage is Fuel Rail Pump – This item is sometimes referred shorted high. to as the High Pressure Fuel Rail Pump. This is a device that supplies fuel under pressure to the fuel 4 –...
  • Page 11 KENR9126 Troubleshooting Section Password – A password is a group of numeric Injector Codes – The injector codes or trim codes characters or a group of alphanumeric characters are numeric codes or alphanumeric codes that are etched or stamped on individual electronic unit that is designed to restrict access to parameters.

  • Page 12: Electronic Service Tools

    Electrical contact with the frame is made and a short circuit results. Perkins electronic service tools are designed to help Signal – The signal is a voltage or a waveform that the service technician: is used in order to transmit information typically from a sensor to the ECM.
  • Page 13 Perkins Electronic Service Tool Electronic Service Tool and the PC requirements for the Electronic Service Tool, refer to the documentation that accompanies your Perkins The Perkins Electronic Service Tool can display the Electronic Service Tool software. following information: • Status of all pressure sensors and temperature sensors •...

  • Page 14: Indicator Lamps

    KENR9126 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 15 KENR9126 Troubleshooting Section On – The lamp will illuminate when a low oil pressure event is detected. The “Warning” lamp and the “Diagnostic” lamp may also illuminate. Low Coolant Level Lamp check – When the keyswitch is turned to ON, the lamp will illuminate for 2 seconds. The lamp will then be extinguished unless there is an active warning.
  • Page 16 KENR9126 Troubleshooting Section Operation of the Indicator Lamps Table 4 Diagnostic Warning 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 illuminate for 2 seconds and the lamps will then engine has not yet been be extinguished.

  • Page 17: Replacing The Ecm

    KENR9126 Troubleshooting Section g02188453 Illustration 4 After all of the active diagnostic codes have been displayed, the “Warning” lamp will be extinguished NOTICE for 2 seconds. The “Warning” lamp will flash twice in Keep all parts clean from contaminants. order to indicate the start of the sequence that will display the logged diagnostic codes.

  • Page 18: Self-Diagnostics

    • Event the PTMI data on the Perkins Secured Internet. Diagnostic Code – When a fault in the electronic 4. Remove power from the ECM. system is detected, the ECM generates a diagnostic code.

  • Page 19: Sensors And Electrical Connectors

    KENR9126 Troubleshooting Section Event Code – An event code is generated by the detection of an abnormal engine operating condition. For example, an event code will be generated if the oil pressure is too low. In this case, the event code indicates the symptom of a fault.
  • Page 20 KENR9126 Troubleshooting Section g02186434 Illustration 5 Typical example of the sensor locations on the engine (1) Water in fuel sensor (6) Intake manifold air temperature sensor (11) Transmission oil temperature sensor (if (2) Electronic Control Module (ECM) (7) Intake manifold pressure sensor equipped) (3) Fuel supply pressure sensor (if equipped) (8) Fuel rail pressure Sensor...
  • Page 21 KENR9126 Troubleshooting Section g02190335 Illustration 6 Detailed views of the sensor locations on the engine...
  • Page 22 KENR9126 Troubleshooting Section Table 5 Function Connector P1 (E-C1) Customer Harness to ECM Connector (64 Pin Connector) P2 (A-C1) Engine Harness to ECM Connector (64 Pin Connector) A-C2 Fuel Rail Pump Solenoid Connector (Two Pin Connector) A-C3 Secondary Speed/Timing Sensor (Two Pin Connector) A-C4 Primary Speed/Timing Sensor (Two Pin Connector) A-C5...

  • Page 23: 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 24 KENR9126 Troubleshooting Section Schematic Diagrams g02196693 Illustration 7 Schematic Diagram for the engine Harness...
  • Page 25 KENR9126 Troubleshooting Section g02201275 Illustration 8...
  • Page 26 KENR9126 Troubleshooting Section g02201274 Illustration 9...
  • Page 27 KENR9126 Troubleshooting Section g02196694 Illustration 10 Schematic Diagram for the application...

  • Page 28: Ecm Harness Connector Terminals

    KENR9126 Troubleshooting Section i03434106 ECM Harness Connector Terminals The Electronic Control Module (ECM) uses connectors that have 64 terminals to interface to the wiring harness. g01784793 Illustration 12 Removal of Terminal Position Assurance Components 1. Remove the connector from the ECM. Refer to g01784773 Illustration 11 Disassembly and Assembly, “Electronic Control...
  • Page 29 KENR9126 Troubleshooting Section 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. Terminal Insertion 1. Push the terminal into the rear of the connector (3) until the terminal engages with the locking device.

  • Page 30: Programming Parameters

    Note: Factory passwords are provided only to 5. Start the “Test ECM Mode” on the electronic Perkins dealers. service tool. Access the feature through the “Service” menu. The electronic service tool will Factory passwords are required to perform each of...

  • Page 31: Flash Programming

    Injector Trim File Note: If you do not have the part number for the flash file, use “PTMI” on the Perkins Intranet. Note: You must have the engine serial number in The electronic service tool is used to load the injector order to search for the part number for the flash file.
  • Page 32 2. Obtain the injector trim file by one of the following methods: • Select “Service Software Files” on the Perkins Internet. • Use the compact disc that is included with a replacement electronic unit injector.

  • Page 33: Customer Specified Parameters

    KENR9126 Troubleshooting Section Customer Specified ECM Identification Parameter Parameters Equipment ID “Equipment ID” is the identification of the equipment i04012393 that is assigned by the customer. The “Equipment Customer Specified ID” is only for reference only by the customer. The “Equipment ID”...
  • Page 34 KENR9126 Troubleshooting Section Exhaust Gas Temperature Sensor Fuel Pressure Sensor Installation Status Installation Status A fuel pressure sensor is an optional sensor input. Programming the “Fuel Pressure Sensor Installation An exhaust gas temperature sensor is an optional Status” parameter to “Enabled” notifies the ECM sensor input.

  • Page 35: Customer Specified Parameters Table

    KENR9126 Troubleshooting Section i04012394 Customer Specified Parameters Table Table 18 Customer Specified Parameters ECM Parameter Possible Values Default Value Engine Rating Parameter “Rating Number” 1 to 2 Low/High Idle Parameters “Low Idle Speed” 600 to 750 rpm 600 rpm ECM Identification Parameter “Equipment ID”...

  • Page 36: Customer Specified Parameters Worksheet

    KENR9126 Troubleshooting Section i04012409 Customer Specified Parameters Worksheet Table 19 Customer Specified Parameters Worksheet Engine Rating Parameter “Rating Numbers” Low Idle Parameters “Low Idle Speed” ECM Identifications Parameters “Equipment ID” Configurable Inputs “Coolant Level Sensor Installation Status” “Fuel/Water Separator Switch Installation Status” “Exhaust Gas Temperature Installation Status”...

  • Page 37: System Configuration Parameters

    KENR9126 Troubleshooting Section System Configuration This code does not need to be programmed when the replacement ECM is for the same engine rating. Parameters If the ECM is for a different engine rating, then the following components may need to be changed: i03436280 pistons, fuel injectors, and other components.

  • Page 38: Troubleshooting Without A Diagnostic Code

    KENR9126 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. i04010429 Alternator Noise i04010431...

  • Page 39: Battery

    KENR9126 Troubleshooting Section • Air intake and exhaust system i04010432 Battery • Fuel supply • Individual malfunctioning cylinders Note: The problem is not an electronic system • Electronic unit injectors problem. Recommended Actions Probable Causes Diagnostic Codes • Charging circuit Check for active diagnostic codes on the electronic •...

  • Page 40: Coolant In Engine Oil

    KENR9126 Troubleshooting Section 2. Ensure that the air filter is clean and serviceable. 11. If the high-pressure fuel lines have a leak, the high-pressure fuel lines must be replaced. 3. Check the air intake and the exhaust system for the following defects: 12.

  • Page 41: Coolant Temperature Is Too High

    KENR9126 Troubleshooting Section • Cylinder head gasket i04010436 Coolant Temperature Is Too • Cylinder head High • Cylinder block Recommended Actions Note: This is not an electronic system fault. Engine Oil Cooler Probable Causes 1. Drain the engine lubricating oil from the engine. •...

  • Page 42: Ecm Will Not Accept Factory Passwords

    KENR9126 Troubleshooting Section Restriction in the Coolant System • Passwords 1. Visually inspect the cooling system for collapsed • Serial numbers hoses and/or other restrictions. • Total tattletale 2. Clean the radiator and flush the radiator. • Reason code Water Temperature Regulator Recommended Actions Check the water temperature regulator for correct operation.

  • Page 43: Electronic Service Tool Will Not Communicate With Ecm

    Wiring to other control modules devices are configured to use the same port, exit or close the software programs for that device. 3. Troubleshoot the Perkins Data Link for possible faults. Refer to Troubleshooting, “Data Link Circuit Electrical Connectors - Test”.

  • Page 44: Engine Cranks But Will Not Start

    KENR9126 Troubleshooting Section Note: If the ECM is not receiving battery voltage, the Note: The following procedure is only applicable ECM will not communicate. if the application is equipped with a display on the control panel. Data Link 1. Check the display on the control panel for active diagnostic codes.
  • Page 45 KENR9126 Troubleshooting Section • Use the electronic service tool to check the 2. Check for fuel supply lines that are restricted. average cranking speed of the engine. If the cranking speed is less than 150 rpm, investigate 3. Check that the low-pressure fuel lines are correctly the cause of the low cranking speed.
  • Page 46 Refer to time. Troubleshooting, “Fuel Rail Pump Solenoid - f. If the Perkins dealer recommends the use Test”. of a test ECM, install a test ECM. Refer to d. If any service has been performed as a result Troubleshooting, “Replacing the ECM”.

  • Page 47: Engine Has Early Wear

    KENR9126 Troubleshooting Section Glow Plugs • Dirt in engine oil Note: Faulty glow plugs will only affect engine starting • Incorrect oil when the ambient temperature is below 5° C (41° F). • Contaminated oil 1. Check the operation of the glow plugs. •...

  • Page 48: Engine Misfires, Runs Rough Or Is Unstable

    KENR9126 Troubleshooting Section 2. Check the diesel fuel for contamination. 2. If the signal is erratic, refer to Troubleshooting, “Digital Throttle Position Sensor Circuit - Test”. Low Oil Pressure 3. If the repairs do not eliminate the fault proceed to “Air Intake and Exhaust System”.

  • Page 49: Engine Oil In Cooling System

    KENR9126 Troubleshooting Section Electronic Unit Injectors 1. Use the electronic service tool to select the correct screen display. Refer to Troubleshooting, “Troubleshooting with a Diagnostic Code”. 1. With the engine speed at a fast idle, use the electronic service tool to isolate one cylinder at 2.

  • Page 50: Engine Speed Does Not Change

    KENR9126 Troubleshooting Section Throttle Position Sensor 4. If there was no obvious signs of a faulty head gasket proceed to “Cylinder Head”. Refer to Troubleshooting, “Analog Throttle Position Sensor Circuit - Test” or Troubleshooting, “Digital Cylinder Head Throttle Position Sensor Circuit - Test” if any of the following diagnostic codes are active: 1.

  • Page 51: Engine Vibration

    KENR9126 Troubleshooting Section Recommended Actions 6. Check that the low-pressure fuel lines are tight and correctly secured. Vibration Damper 7. Check the fuel filters. Check the vibration damper for damage. Install a 8. Check the diesel fuel for contamination. new vibration damper, if necessary. Inspect the mounting bolts for damage and/or for wear.

  • Page 52: Engine Will Not Crank

    KENR9126 Troubleshooting Section Recommended Repairs Malfunctioning Individual Cylinder 1. With the engine speed at a fast idle, use the Battery Cables and/or Batteries electronic service tool to isolate one cylinder at a time. Note if there is any reduction in engine 1.

  • Page 53: Excessive Black Smoke

    KENR9126 Troubleshooting Section Air Intake System or Exhaust System • Bent components 4. If the crankshaft rotates correctly and no fluid is 1. Check the air filter restriction indicator, if equipped. expelled, install the glow plugs. 2. Ensure that the air filter is clean and serviceable. i04010460 3.

  • Page 54: Excessive Engine Oil Consumption

    KENR9126 Troubleshooting Section Low Compression (Cylinder Pressure) Individual Malfunctioning Cylinder 1. Perform a compression test. 1. With the engine speed at a fast idle, use the electronic service tool to isolate one cylinder at 2. If low compression is noted on any cylinders, a time.

  • Page 55: Excessive Fuel Consumption

    KENR9126 Troubleshooting Section 4. If no oil leaks are identified, refer to “Engine 2. Check the turbocharger for evidence of internal Crankcase Breather”. oil leaks. 3. If necessary, replace the turbocharger. Engine Crankcase Breather 4. Check that the repairs have eliminated the faults. 1.
  • Page 56 KENR9126 Troubleshooting Section Low Engine Temperature • Reduced pressure of intake air • Excessive valve lash 1. The operating temperature of the engine will affect the rate of fuel consumption. Operation of the • Failure of the primary speed/timing sensor engine below the correct temperature will increase fuel consumption.

  • Page 57: Excessive Valve Lash

    KENR9126 Troubleshooting Section 3. Repair all defects. Verify that the repair has i04010463 eliminated the fault. Excessive Valve Lash Reduced Pressure of Intake Air 1. If the pressure of the intake air at the intake Note: This is not an electronic system fault. manifold is lower than normal, either the speed of the engine will need to be higher or more fuel Probable Causes...

  • Page 58: Excessive White Smoke

    KENR9126 Troubleshooting Section Note: Diesel fuel with a low cetane value is likely to i04010464 cause white smoke. Excessive White Smoke 2. If the repair does not eliminate the fault refer to “Valve Lash”. Note: Some white smoke may be present during Valve Lash cold start-up conditions when the engine is operating normally.

  • Page 59: Exhaust Temperature Is High

    KENR9126 Troubleshooting Section Recommended Actions i04010465 Exhaust Temperature Is High Leaking Seals on the Case of the Unit Injector or on the Barrel of the Unit Injector Probable Causes Look for signs of damage to the seals for the unit injectors.

  • Page 60: Intermittent Low Power Or Power Cutout

    KENR9126 Troubleshooting Section Recommended Actions 1. Visually check the fuel tank for fuel. The fuel gauge may be faulty. Diagnostic Codes 2. Ensure that the fuel supply valve (if equipped) is in the full OPEN position. Check for any event and active diagnostic codes on the electronic service tool.
  • Page 61 KENR9126 Troubleshooting Section Recommended Actions 6. Check that the low pressure fuel lines are tight and secured properly. NOTICE 7. Check the fuel filters. Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two 8.

  • Page 62: Low Engine Oil Pressure

    KENR9126 Troubleshooting Section Engine Oil Pressure Gauge (if equipped) i04010468 Low Engine Oil Pressure 1. Certain applications may have an engine oil pressure gauge installed or can monitor the engine oil pressure from an electronic display. Check the actual engine oil pressure with a calibrated test NOTICE gauge.

  • Page 63: Low Power/Poor Or No Response To Throttle

    KENR9126 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. 30 seconds.
  • Page 64 KENR9126 Troubleshooting Section Throttle Signal 8. If the fault has not been eliminated, proceed to “Fuel Supply”. Monitor the status for “Throttle Position” on the electronic service tool. Verify that the status for Fuel Supply “Throttle Position” is stable and that the engine is able to reach high idle speed.

  • Page 65: Mechanical Noise (Knock) In Engine

    KENR9126 Troubleshooting Section • 5. If the repair does not eliminate the fault refer to Connecting rod and main bearings “Individual Malfunctioning Cylinders”. Recommended Actions Individual Malfunctioning Cylinders Accessory Equipment 1. Use the electronic service tool to perform the “Cylinder Cut-out Test”. Note if there is any 1.

  • Page 66: Poor Acceleration Or Response

    KENR9126 Troubleshooting Section Recommended Actions i04010491 Poor Acceleration or Response Fuel Quality 1. Check the fuel quality. Probable Causes 2. If unsatisfactory fuel is found, perform the following procedure. • Diagnostic codes and event codes a. Drain the fuel system. •...

  • Page 67: Transmission Oil Pressure Is High

    KENR9126 Troubleshooting Section Throttle Signal Fuel Supply Monitor the status for “Throttle Position” on the 1. Visually check the fuel level in the fuel tank. Do not electronic service tool. Verify that the status for rely on the fuel gauge only. If necessary, add fuel “Throttle Position”...

  • Page 68: Transmission Oil Temperature Is High

    KENR9126 Troubleshooting Section 3. Repair the relief valve or replace the relief valve. Refer to the service literature from the Original Equipment Manufacturer (OEM) for additional information on the transmission for the vessel. i04012484 Transmission Oil Temperature Is High Probable Causes •...

  • Page 69: Troubleshooting With A Diagnostic Code

    KENR9126 Troubleshooting Section Troubleshooting with a Suspect Parameter Number (SPN) – The SPN is a code which is assigned to each component in order Diagnostic Code to identify data via the data link to the ECM. This is used on the diagnostics for the CAN data link. Refer to Troubleshooting, “Diagnostic Code Cross i04015352 Reference”...
  • Page 70 KENR9126 Troubleshooting Section Logged Diagnostic Codes When the ECM generates a diagnostic code, the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock. Each ECM will record the following information when a code is generated: •...

  • Page 71: Diagnostic Code Cross Reference

    KENR9126 Troubleshooting Section i04010594 Diagnostic Code Cross Reference Table 20 3rd Party Device Flash CDL Code Description J1939 Code Code No Diagnostic Code Detected 0001-02 Cylinder #1 Injector erratic, intermittent, or incorrect 651-2 0001-05 Cylinder #1 Injector current below normal 651-5 0001-06 Cylinder #1 Injector current above normal...
  • Page 72 KENR9126 Troubleshooting Section (Table 20, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 0100-10 100-10 Engine Oil Pressure Sensor abnormal rate of change 0110-03 Engine Coolant Temperature Sensor voltage above normal 110-03 0110-04 Engine Coolant Temperature Sensor voltage below normal 110-04 0127-03 Transmission Oil Pressure open/short to +batt...

  • Page 73: No Diagnostic Codes Detected

    KENR9126 Troubleshooting Section (Table 20, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 1797-04 157-04 Fuel Rail Pressure Sensor voltage below normal 1834-02 Ignition Key Switch loss of signal 2246-05 Glow Plug Start Aid Relay current below normal 626-05 2246-06 Glow Plug Start Aid Relay current above normal...

  • Page 74: Cid 0001 Fmi 02

    KENR9126 Troubleshooting Section Results: i04053149 CID 0001 FMI 05 • OK – STOP. i02655551 Conditions Which Generate This Code: CID 0001 FMI 02 This diagnostic code is designed to indicate an open circuit (low current). The open circuit can be in either the solenoid or the wiring for the electronic unit Conditions Which Generate This Code: injector for No.

  • Page 75: Cid 0001 Fmi 06

    KENR9126 Troubleshooting Section i04053150 i03449840 CID 0001 FMI 06 CID 0001 FMI 07 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).

  • Page 76: Cid 0002 Fmi 05

    KENR9126 Troubleshooting Section • Diagnostic code 0190-08 is not active. An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring • No 0110 diagnostic codes are active. that is unique to the electronic unit injector will prevent that individual electronic unit injector from operating.

  • Page 77: Cid 0002 Fmi 07

    KENR9126 Troubleshooting Section The ECM will continue to attempt to operate the i02655554 electronic unit injector after the diagnostic code CID 0003 FMI 02 has been logged but a short circuit will prevent the operation of the electronic unit injector. Perform the following diagnostic procedure: “Injector Conditions Which Generate This Code: Solenoid Circuit - Test”...

  • Page 78: Cid 0003 Fmi 06

    KENR9126 Troubleshooting Section • A low current condition (open circuit) for each of System Response: five consecutive attempts to operate If equipped, the warning light will come on. The ECM • Battery voltage is higher than 9 VDC for 2 seconds. will log the diagnostic code.

  • Page 79: Cid 0004 Fmi 02

    KENR9126 Troubleshooting Section Replace the suspect electronic unit injector. Refer i04053174 to Disassembly and Assembly, “Electronic Unit CID 0004 FMI 05 Injector - Remove” and Disassembly and Assembly, “Electronic Unit Injector - Install”. Use the electronic service tool to perform the Conditions Which Generate This Code: Verification Test for the Fuel System.

  • Page 80: Cid 0004 Fmi 06

    KENR9126 Troubleshooting Section i04053176 i03449922 CID 0004 FMI 06 CID 0004 FMI 07 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).

  • Page 81: Cid 0005 Fmi 05

    KENR9126 Troubleshooting Section • No 0041 diagnostic codes are active. Troubleshooting: • No 0262 diagnostic codes are active. When an injector cutout test is performed, a faulty electronic unit injector will indicate a low reading in • Diagnostic code 0190-08 is not active. comparison with the other electronic unit injectors.

  • Page 82: Cid 0005 Fmi 07

    KENR9126 Troubleshooting Section Troubleshooting: Use the electronic service tool to perform the Verification Test on the fuel system. When an injector cutout test is performed, a faulty electronic unit injector will indicate a low reading in Perform the following diagnostic procedure: “None” comparison with the other electronic unit injectors.

  • Page 83: Cid 0006 Fmi 05

    KENR9126 Troubleshooting Section i04053185 i04053192 CID 0006 FMI 05 CID 0006 FMI 06 Conditions Which Generate This Code: Conditions Which Generate This Code: This diagnostic code is applicable to six cylinder This diagnostic code is applicable to six cylinder engines only. engines only.

  • Page 84: Cid 0006 Fmi 07

    KENR9126 Troubleshooting Section System Response: i03449944 CID 0006 FMI 07 The ECM will log the diagnostic code and the diagnostic lamp will illuminate while this diagnostic code is active. Conditions Which Generate This Code: Possible Performance Effect: This diagnostic code is applicable to six cylinder The engine may be limited to low idle.

  • Page 85: Cid 0091 Fmi 08

    KENR9126 Troubleshooting Section Results: System Response: • OK – STOP. The Electronic Control Module (ECM) will log the diagnostic code. The ECM flags the throttle position as invalid data and a default value of zero percent i04015670 is used. CID 0091 FMI 08 Possible Performance Effect: •...

  • Page 86: Cid 0096 Fmi 03

    KENR9126 Troubleshooting Section System Response: System Response: The ECM will log the diagnostic code. The ECM flags The Electronic Control Module (ECM) will log the fuel pressure as invalid data and a default value is diagnostic code. used. Possible Performance Effect: Possible Performance Effect: •...

  • Page 87: Cid 0100 Fmi 04

    KENR9126 Troubleshooting Section • Results: No 0262 diagnostic codes are active for the 5 V supply. • OK – STOP. • The engine speed is greater than 600 rpm. i04015731 • The engine oil pressure signal is within the limits of CID 0100 FMI 04 410 kPa (59 psi) to 520 kPa (75 psi) with a pressure variation of less than 1.68 kPa (0.25 psi)for more...

  • Page 88: Cid 0110 Fmi 04

    KENR9126 Troubleshooting Section The ECM will default to 90 °C (194 °F) for engine Troubleshooting: coolant temperature. “Voltage Above Normal” will be displayed next to the status for “Engine Coolant The diagnostic code will detect an excessively low Temperature” on the electronic service tool. voltage from the engine coolant temperature sensor.

  • Page 89: Cid 0168 Fmi 00

    KENR9126 Troubleshooting Section • Troubleshooting: The engine is not cranking. Perform the following diagnostic procedure: “Engine • The engine is running for more than 3 seconds. Pressure Sensor Open or Short Circuit - Test” • The battery voltage to the ECM is below 9 VDC for Results: more than 0.5 seconds.

  • Page 90: Cid 0172 Fmi 03

    KENR9126 Troubleshooting Section • The diagnostic lamp may come on. Black smoke Possible Performance Effect: • Poor acceleration under load The engine may experience changes in the engine Troubleshooting: rpm. The engine may experience intermittent engine shutdowns or complete engine shutdowns while This fault can be caused by an open circuit or a short the conditions that cause this diagnostic code are to a power source.

  • Page 91: Cid 0174 Fmi 03

    KENR9126 Troubleshooting Section Troubleshooting: Troubleshooting: This fault can be caused by a sensor that is shorted Perform the following diagnostic procedure: “Engine to ground or a sensor that is internally shorted. Temperature Sensor Open or Short Circuit - Test” Perform the following diagnostic procedure: “Engine Results: Temperature Sensor Open or Short Circuit - Test”...

  • Page 92: Cid 0190 Fmi 08

    KENR9126 Troubleshooting Section Troubleshooting: i04015824 CID 0253 FMI 02 Perform the following diagnostic procedure: “Transmission Oil Temperature Sensor Open or Short Circuit - Test” Conditions Which Generate This Code: Results: The Electronic Control Module (ECM) detects • OK – STOP. incorrect engine software.

  • Page 93: Cid 0262 Fmi 03

    KENR9126 Troubleshooting Section System Response: i03451888 CID 0262 FMI 04 If equipped, the diagnostic light will come on. This code will not be logged. Possible Performance Effect: Conditions Which Generate This Code: The pressure in the fuel rail may be unstable and the The Engine Control Module (ECM) detects the engine may not run smoothly.

  • Page 94: Cid 0342 Fmi 08

    KENR9126 Troubleshooting Section • All of the injector trim files are not loaded into the Possible Performance Effect: ECM. Engine performance and emissions are affected. If the signal from the secondary speed/timing sensor is lost and the engine is stopped, the engine will not System Response: restart.

  • Page 95: Cid 0526 Fmi 06

    KENR9126 Troubleshooting Section The Electronic Control Module (ECM) detects the Possible Performance Effect: following conditions: The engine will be derated while this diagnostic code • A low current condition in the output from the ECM is active. to the solenoid for the wastegate regulator Troubleshooting: •...

  • Page 96: Cid 0535 Fmi 03

    KENR9126 Troubleshooting Section Troubleshooting: i04012473 CID 0535 FMI 04 This diagnostic code will detect a mechanical problem in the intake air system. The electronic part of the control system will be operating correctly. Conditions Which Generate This Code: Perform the following diagnostic procedure: “Systems Operation, Testing and Adjusting, “Turbocharger - The Electronic Control Module (ECM) detects the Inspect””...

  • Page 97: Cid 0774 Fmi 13

    KENR9126 Troubleshooting Section Possible Performance Effect: System Response: • The engine speed is limited to low idle if the If equipped, the diagnostic light will come on and the secondary throttle is in operation. ECM will log the diagnostic code. Troubleshooting: Possible Performance Effect: Perform the following diagnostic procedure: “Throttle...

  • Page 98: Cid 1785 Fmi 03

    KENR9126 Troubleshooting Section • The signal voltage from the intake manifold i04016595 pressure sensor is less than 0.2 VDC for at least CID 1785 FMI 03 2 seconds. • The ECM has been powered for 2 seconds. Conditions Which Generate This Code: •...

  • Page 99: Cid 1797 Fmi 03

    KENR9126 Troubleshooting Section • No 0262 codes for the 5 V supply are active. Possible Performance Effect: • Diagnostic code 0168-01 is not active. The engine will be derated. System Response: Troubleshooting: If equipped, the diagnostic light will come on. The This diagnostic code detects an excessively high diagnostic code will be logged.

  • Page 100: Cid 1834 Fmi 02

    KENR9126 Troubleshooting Section System Response: i04016609 CID 1834 FMI 02 If equipped, the diagnostic light will come on. The diagnostic code will be logged. An ECM that was previously blank will require a total of 2 hours of operation before the diagnostic code will be logged. Conditions Which Generate This Code: Possible Performance Effect: The Electronic Control Module (ECM) detects the...
  • Page 101 KENR9126 Troubleshooting Section The engine may be difficult to start in cold temperatures and the exhaust may emit white smoke. Troubleshooting: This diagnostic code detects an excessively high current in the circuit for the starting aid relay. Perform the following diagnostic procedure: “Starting Aid (Glow Plug) Relay Circuit - Test”...

  • Page 102: Troubleshooting With An Event Code

    KENR9126 Troubleshooting Section Troubleshooting with an Event Code i04021987 Event Codes The ECM can log events. Events refer to engine operating conditions such as low oil pressure or high coolant temperature. Logged events usually indicate a mechanical problem instead of an electronic system problem.
  • Page 103 KENR9126 Troubleshooting Section Table 21 Trip Points for the Monitoring System Delay Time in Seconds Trip Point Default Action Condition Default Default State E360-(1) Low Engine Oil Warning dependent Pressure Warning value E360-(2) Low Engine Oil Pressure Derate Derate dependent value E361-(1) High Engine 103 °C...

  • Page 104: E096 High Fuel Pressure

    KENR9126 Troubleshooting Section Possible Performance Effect: Table 22 Trip Points for Low Oil Pressure Warning Engine performance is not affected. 0 rpm 0 kPa (0 psi) Check the Low Pressure Fuel System 500 rpm 0 kPa (0 psi) 1600 rpm 154 kPa (22 psi) Check the components of the low-pressure fuel system.

  • Page 105: E119 Low Fuel Level

    KENR9126 Troubleshooting Section Results: System Response: • OK – There is a problem with the transmission. The Electronic Control Module (ECM) will log the code. Repair: Make the necessary repairs. Verify that the problem is resolved. Possible Performance Effect: • STOP.

  • Page 106: E198 Low Fuel Pressure

    KENR9126 Troubleshooting Section Expected Result: System Response: The event occurred because of abnormal engine The ECM will log the code. operation. Possible Performance Effect: Results: Engine performance is not affected. • OK – The event occurred because of abnormal Check the Low Pressure Fuel System engine operation.

  • Page 107: E268 Unexpected Engine Shutdown

    KENR9126 Troubleshooting Section • None Not OK – There is a problem with the air intake system. Troubleshooting: Repair: Repair the problem. Ensure that the repair Refer to Systems Operation, Testing and Adjusting eliminates the problem. manual, “Fuel System - Inspect”. STOP.

  • Page 108: E361 High Engine Coolant Temperature

    KENR9126 Troubleshooting Section Possible Performance Effect: 360-1 Engine operation is not affected. 360-2 The ECM will derate power by 17.0 percent per second up to a maximum of 100 percent while the derate is active. Troubleshooting: Refer to Troubleshooting, “Low Engine Oil Pressure”. Results: •...

  • Page 109: E362 Engine Overspeed

    KENR9126 Troubleshooting Section None i04018249 E363 High Fuel Supply E361-2 Temperature The ECM will derate the power at 1 percent per second. Troubleshooting: Conditions Which Generate This Code: Refer to Troubleshooting, “Coolant Temperature Is This event code will only be generated if the switch Too High”.

  • Page 110: E396 High Fuel Rail Pressure

    KENR9126 Troubleshooting Section i04016612 i04016613 E396 High Fuel Rail Pressure E398 Low Fuel Rail Pressure Conditions Which Generate This Code: Conditions Which Generate This Code: The Electronic Control Module (ECM) detects The Electronic Control Module (ECM) detects low excessive fuel rail pressure under the following fuel rail pressure under the following conditions: conditions: •...

  • Page 111: E539 High Intake Manifold Air Temperature

    KENR9126 Troubleshooting Section Results: • OK – STOP. i04012516 E539 High Intake Manifold Air Temperature Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a high air temperature in the intake manifold under the following conditions: • The engine has been running for more than 3 minutes.

  • Page 112: E877 High Transmission Oil Temperature

    KENR9126 Troubleshooting Section System Response: i04018251 E877 High Transmission Oil The Electronic Control Module (ECM) will log the Temperature event. Possible Performance Effect: • The engine will derate to 20 percent and key cycle Conditions Which Generate This Code: is required to clear the engine derate. The transmission oil temperature has exceeded the Troubleshooting: trip point.

  • Page 113: E2143 Low Engine Coolant Level

    KENR9126 Troubleshooting Section • The intake manifold pressure has exceeded the The ECM detects a low coolant level in the engine trip point. Refer to Troubleshooting, “Event Codes” for more than 30 seconds. for the trip point. System Response: The Electronic Control Module (ECM) will log the event.
  • Page 114 KENR9126 Troubleshooting Section Table 28 Low Engine Coolant Level Table E2143-1 E2143-2 Trip Point Delay to Activation 30 seconds 30 seconds Reset Time 30 seconds 30 seconds System Response: If equipped, the shutdown lamp and the warning lamp will come on. The event code will be logged.

  • Page 115: Diagnostic Functional Tests

    KENR9126 Troubleshooting Section Diagnostic Functional • A suspect sensor Tests • A suspect ECM i04012485 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 116 KENR9126 Troubleshooting Section Table 29 P1 Pin Connections Sensor Pin Function Fuel Pressure Sensor Exhaust Gas Temperature Sensor Volts (5 V) Ground Signal g02199234 Illustration 15 Typical example Table 30 P2 Pin Connections Function Fuel Rail Sensor Pin Intake Manifold Oil Pressure Transmission Oil Pressure...
  • Page 117 KENR9126 Troubleshooting Section g02193216 Illustration 16 Typical example g01173224 g01173225 Illustration 17 Illustration 18 Typical example of the fuel rail pressure sensor Typical example of the intake manifold pressure sensor (1) Voltage supply (Vs) (1) Voltage Supply (Vs) (2) Ground (GND) (2) Ground (GND) (3) Signal (SIG) (3) Signal (SIG)
  • Page 118 KENR9126 Troubleshooting Section g01173226 g01173225 Illustration 19 Illustration 22 Typical example of the oil pressure sensor Typical example of the exhaust gas temperature sensor (1) Voltage Supply (Vs) (1) Voltage Supply (Vs) (2) Ground (GND) (2) Ground (GND) (3) Signal (SIG) (3) Signal (SIG) g01173226 Illustration 20...
  • Page 119 KENR9126 Troubleshooting Section g02199236 Illustration 23 Typical example of the P1 pressure sensor pin locations (33) Voltage supply (5 V) Fuel Pressure (41) Ground (GND) Fuel Pressure Sensor (54) Signal (SIG) Exhaust Gas Temperature Sensor (42) Ground (GND) Exhaust Gas Sensor (34) Voltage supply (5 V) Exhaust Gas Temperature Sensor...
  • Page 120 KENR9126 Troubleshooting Section • Abrasion Expected Result: • Corrosion One of the following diagnostic codes is active: • Incorrect attachment • 0262-03 5 Volt Sensor DC Power Supply voltage above normal C. Refer to Troubleshooting, “Electrical Connectors • - Inspect”. 0262-04 5 Volt Sensor DC Power Supply voltage below normal D.
  • Page 121 KENR9126 Troubleshooting Section Test Step 4. Install a New Sensor • Engine temperature sensors A. Remove the connector from the suspect sensor Expected Result: and connect the connector to a replacement sensor. Do not install the replacement sensor to Diagnostic code 0262-04 is not active. A “voltage the engine.

  • Page 122: Can Data Link Circuit - Test

    KENR9126 Troubleshooting Section • Expected Result: Not OK – At least one intermittent fault was indicated. The voltage is 5.0 ± 0.16 VDC. Repair: Repair the harness or the connector. Results: Use the electronic service tool in order to clear all •...
  • Page 123 KENR9126 Troubleshooting Section g02193373 Illustration 25 Schematic for the CAN data link Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove the electrical power from the ECM. B. Thoroughly inspect connectors for the ECM, electronic service tool and the customer.
  • Page 124 KENR9126 Troubleshooting Section g02193395 Illustration 26 P1 terminals that are associated with the CAN data link (21) CAN data link − (22) CAN shield (20) CAN data link + E. Check the wiring harnesses for abrasion, for corrosion and for pinch points. Expected Result: All connectors, pins and sockets are completely coupled and/or inserted.
  • Page 125 KENR9126 Troubleshooting Section E. Disconnect the P1 connector. Table 31 Resistance Measurements for the CAN Data Link Note: Wiggle the harness during the following measurements in order to reveal an intermittent Connector and Terminal Terminal condition. P1-20 (CAN data link +) All of the other terminals on F.

  • Page 126: Coolant Level Sensor Circuit - Test

    KENR9126 Troubleshooting Section • Not OK – The resistance is more than ten Ohms. i04010976 There is an open circuit or excessive resistance in Coolant Level Sensor Circuit the circuit. There may be a problem in a connector. - Test Repair: Repair the wiring and/or the connector.
  • Page 127 KENR9126 Troubleshooting Section g02192043 Illustration 29 Schematic for the coolant level sensor Pressurized System: Hot coolant can cause seri- ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres- sure.
  • Page 128 KENR9126 Troubleshooting Section g02192045 Illustration 31 P1 terminals that are associated with the coolant level sensor (P1-45) Coolant level C. Perform a 45 N (10 lb) pull test on each of the B. Restore the electrical power to the ECM. wires that are associated with the circuit for the coolant level sensor.
  • Page 129 KENR9126 Troubleshooting Section Repair: Refer to the diagnostic functional test Results: Troubleshooting, “Digital Sensor Supply Circuit - Test”. • OK – The status is “Low” when the sensor is disconnected. Proceed to Test Step 5. STOP. • Not OK – The status is “OK” when the sensor is Test Step 3.
  • Page 130 KENR9126 Troubleshooting Section If the status for the coolant level is “Low”, Note: Wiggle the harness during the following connect the sensor. Fill the cooling system. measurements in order to reveal an intermittent Return the engine to service. condition. STOP. B.

  • Page 131: Data Link Circuit - Test

    KENR9126 Troubleshooting Section Expected Result: The data link is the standard data link that is used by the ECM in order to communicate with the electronic The status is “Low” when the jumper wire is not service tool. connected. The status is “OK” when the jumper wire is connected.
  • Page 132 KENR9126 Troubleshooting Section g02192873 Illustration 33 Schematic of the diagnostic connector g02273797 Illustration 34 Typical view of the pin locations on the P1 connector (1) Battery + (22) J1939 Shield (40) Keyswitch (20) J1939 + (23) Data link + (21) J1939 - (24) Data link - Test Step 1.
  • Page 133 KENR9126 Troubleshooting Section Test Step 3. Check the Wiring of the Expected Result: Diagnostic Connector All connectors, pins, and sockets should be completely coupled and/or inserted. The harness should be free of corrosion, abrasion and/or pinch points. Results: • OK – Proceed to Test Step 2. •...
  • Page 134 KENR9126 Troubleshooting Section Test Step 6. Change the Components of Results: the Electronic Service Tool • OK – The diagnostic connector is currently receiving the correct voltage. Proceed to Test Step A. If another electronic engine is available, connect the electronic service tool to the other engine. Ensure that the same cables are used.
  • Page 135 KENR9126 Troubleshooting Section Test Step 7. Connect the Electronic Service Tool and the ECM to another Battery 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 the in-line fuse has been removed from the +Battery...
  • Page 136 KENR9126 Troubleshooting Section g02192874 Illustration 36 Schematic of the bypass harness connector...

  • Page 137: Ecm Memory - Test

    KENR9126 Troubleshooting Section g01802213 Illustration 37 Typical view of the pin locations on the P1 connector for the diagnostic and data link connectors (1) Battery ground (GND) (9) Battery ground (GND) (21) J1939 (CAN) - (2) Battery ground (GND) (10) Battery ground (GND) (23) Data link + (3) Battery ground (GND) (15) Battery +...

  • Page 138: Electrical Connectors - Inspect

    KENR9126 Troubleshooting Section • The flash file in the Electronic Control Module (ECM) Refer to Troubleshooting, “ECM Harness is from the wrong engine family. The engine will not Connector Terminals” in order to service the start. connectors for the Electronic Control Module (ECM).
  • Page 139 KENR9126 Troubleshooting Section g01131276 g01131165 Illustration 39 Illustration 41 Diagram for the installation of a connector plug (typical example) Seal for ECM connector (typical example) (1) ECM connector C. Disconnect the suspect connector and inspect the (2) Correctly inserted plug (3) Incorrectly inserted plug connector seal.
  • Page 140 KENR9126 Troubleshooting Section Expected Result: Expected Result: The harness, connectors, and seals are in good The wires are free of abrasion, nicks and cuts and condition. There is no evidence of moisture in the the harness is correctly clamped. connectors. Results: Results: •...
  • Page 141 KENR9126 Troubleshooting Section Test Step 4. Perform a Pull Test on Each Test Step 5. Check Individual Pin Wire Terminal Connection Retention into the Socket g01802454 g01802455 Illustration 42 Illustration 43 A typical example of the lock wedge. Diagram for testing pin retention (1) Lock wedge A.

  • Page 142: Electrical Power Supply Circuit - Test

    KENR9126 Troubleshooting Section Test Step 8. Perform the “Wiggle Test” Results: on the Electronic Service Tool • OK – The connectors are in good repair. Proceed to Test Step 7. A. Select the “Wiggle Test” from the diagnostic tests on the electronic service tool. •...
  • Page 143 KENR9126 Troubleshooting Section Use this test if there are intermittent engine shutdowns or if a difficulty in starting is not accompanied by loss of electrical accessories. Engine shutdowns that are accompanied by a loss of other electrical accessories indicate a problem in the keyswitch.
  • Page 144 KENR9126 Troubleshooting Section g02199433 Illustration 45 (P1-1) Negative battery (P1-10) Negative battery for communications (P1-23) Data link positive (P1-2) Negative battery adaptor (P1-24) Data link negative (P1-3) Negative battery (P1-15) Unswitched positive battery (P1-39) Alternator charging (P1-7) Unswitched positive battery (P1-20) J1939 data link positive (P1-40) Keyswitch (P1-8) Unswitched positive battery...
  • Page 145 KENR9126 Troubleshooting Section F. Measure the voltage between P1-15 (Unswitched Repair: Recharge or replace the faulty batteries. Positive Battery) and P1-3 (Negative Battery). Verify that the repair eliminates the problem. G. Measure the voltage between P1-40 (Keyswitch) STOP. and P1-3 (Negative Battery). Test Step 4.

  • Page 146: Engine Pressure Sensor Open Or Short Circuit - Test

    KENR9126 Troubleshooting Section The troubleshooting procedures for the diagnostic i04010989 codes of each pressure sensor are identical. The 5 Engine Pressure Sensor Open V sensor supply provides power to all 5 V sensors. or Short Circuit - Test The Electronic Control Module (ECM) supplies 5.0 ± 0.2 VDC to terminal “A”...
  • Page 147 KENR9126 Troubleshooting Section g02256933 Illustration 46 Typical example of the schematic for the sensors g02192913 Illustration 47 Typical example of the schematic for the sensors...
  • Page 148 KENR9126 Troubleshooting Section g02256973 Illustration 48 Typical view of the P1 pressure sensor pin locations (33) Ground (GND) Fuel Rail Pressure (41) Voltage supply (+5 VDC) Fuel Rail (56) Signal (SIG) Fuel Rail Pressure Sensor Sensor Pressure Sensor g02192914 Illustration 49 Typical view of the P2 pressure sensor pin locations (38) Ground (GND) Intake Manifold Pressure (46) Voltage supply (+5 VDC) Intake...
  • Page 149 KENR9126 Troubleshooting Section g01170309 g01170309 Illustration 50 Illustration 53 Fuel rail pressure sensor Typical example of the fuel pressure sensor (1) Voltage supply (+5 VDC) (1) Voltage supply (+5 VDC) (2) Ground (GND) (2) Ground (GND) (3) Signal (SIG) (3) Signal (SIG) g01170310 g01170311 Illustration 51...
  • Page 150 KENR9126 Troubleshooting Section Test Step 2. Inspect Electrical Connectors • 0094-03 Fuel Pressure Sensor voltage above And Wiring normal • 0094-04 Fuel Pressure Sensor voltage below A. Thoroughly inspect the terminal connections on normal the P2/J2 ECM sensor connectors. • 0100-03 Engine Oil Pressure Sensor voltage B.
  • Page 151 KENR9126 Troubleshooting Section Test Step 3. Verify that the Diagnostic Results: Code is Still Active • OK – A “Voltage Above Normal” diagnostic code was active before disconnecting the sensor. An A. Turn the keyswitch to the ON position. Wait at “Voltage Below Normal”...
  • Page 152 KENR9126 Troubleshooting Section E. Use the electronic service tool to check for a short 4. Use the electronic service tool in order to clear circuit diagnostic code. The new sensor should be all logged diagnostic codes and then verify that connected to the harness at this time.
  • Page 153 KENR9126 Troubleshooting Section Results: Note: If an engine sensor harness bypass is being made, crimp a socket on one end in order to connect • OK – The ECM is operating correctly. Proceed to to the ECM. Crimp either a pin or a socket on the Test Step 9.

  • Page 154: Engine Speed/Timing Sensor Circuit - Test

    KENR9126 Troubleshooting Section The loss of signal to the primary sensor and/or the i04010992 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 155 KENR9126 Troubleshooting Section Table 33 P2/J2 Pin Connections Function Sensor Pin Primary Sensor Secondary Sensor +8 Volt Supply Signal g01803493 Illustration 55 The schematic for the speed/timing sensors g01803494 Illustration 56 Pin locations on the P2 connector for the speed/timing sensors (10) Speed/timing sensor supply (+8 Volts (52) Primary speed/timing sensor signal (53) Secondary speed/timing sensor signal...
  • Page 156 KENR9126 Troubleshooting Section g01803516 Illustration 57 Detailed view of the sensor locations on the engine (1) Primary speed/timing sensor (2) Secondary speed/timing sensor g01212995 Illustration 58 Typical example of the speed/timing sensors (1) Voltage Supply (+8 Volts DC) (2) Signal (Sig) Test Step 1.
  • Page 157 KENR9126 Troubleshooting Section • Lubricate the “O” ring with clean engine B. Disconnect the P2 connector. Disconnect the lubricating oil. connector for the primary speed/timing sensor. Disconnect the connector for the secondary • Ensure that the plug for the sensor has a seal speed/timing sensor.
  • Page 158 KENR9126 Troubleshooting Section Results: Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the • OK – The harness does not have an open circuit. repair eliminates the fault. Proceed to Test Step 6. STOP.

  • Page 159: Engine Temperature Sensor Open Or Short Circuit - Test

    KENR9126 Troubleshooting Section C. If a sensor must be replaced or a sensor must be C. If the Technical Help Desk recommends the reinstalled, complete all of the following tasks: use of a test ECM, install a test ECM. Refer to Troubleshooting, “Replacing the ECM”.
  • Page 160 KENR9126 Troubleshooting Section This procedure covers open circuit diagnostic codes The ECM continuously outputs a pull-up voltage on and short circuit diagnostic codes that are associated the circuit for the sensor signal wire. The ECM uses with the following sensors: this pull-up voltage in order to detect an open in the signal circuit.
  • Page 161 KENR9126 Troubleshooting Section g02199533 Illustration 59 Schematic for the temperature sensors g02199535 Illustration 60 Typical view of the P2 pin locations for the temperature sensors (36) Signal (SIG) Fuel Temperature Sensor (43) Signal (SIG) Coolant Temperature (49) Signal (SIG) Transmission Oil (37) Ground (GND) Intake Manifold Air Sensor Temperature Sensor...
  • Page 162 KENR9126 Troubleshooting Section Results: • Yes – Proceed to Test Step 2. • No – The fault is intermittent. Proceed to Test Step Test Step 2. Inspect Electrical Connectors And Wiring A. Thoroughly inspect ECM engine harness connector P2 and the suspect sensor connector. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
  • Page 163 KENR9126 Troubleshooting Section C. Determine if the fault is related to an “Voltage Connect the sensor and verify that the fault returns. Above Normal” diagnostic code or a “Voltage If the fault returns, the sensor is faulty. Below Normal” diagnostic code. Replace the sensor.
  • Page 164 KENR9126 Troubleshooting Section 1. Temporarily connect the suspect sensor. H. Remove the suspect sensor signal pin from the P2 connector, either pin P2:42 for the intake manifold 2. If the diagnostic code remains active, replace temperature sensor or pin P2:43 for the coolant the sensor.

  • Page 165: Engine Temperature Sensor Open Or Short Circuit - Test

    Test Step 7. Bypass The Harness Wiring Test Step 8. Perform the “Wiggle Test” on Between The ECM And The Sensor the Perkins Electronic Service Tool (EST) Connector A. Select the “Wiggle Test” from the diagnostic tests A. Turn the keyswitch to the OFF position.
  • Page 166 KENR9126 Troubleshooting Section • 0535-04 Exhaust Gas Temperature Sensor voltage below normal Pull-up Voltage The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. The ECM uses this pull-up voltage in order to detect an open in the signal circuit.
  • Page 167 KENR9126 Troubleshooting Section g02193016 Illustration 64 A typical view of the P1 connector pin locations. (34) Sensor return (42) Sensor +5 Volt supply (54) Sensor signal Test Step 1. Inspect Electrical Connectors • Not OK – There is a fault in the connectors and/or And Wiring wiring.
  • Page 168 KENR9126 Troubleshooting Section • Expected Result: Not OK – A 0535-3 diagnostic code is active at this time. Proceed to Test Step 5. The voltage measurement is 5.0 ± 0.2 Volts DC. Test Step 4. Disconnect the Sensor in Order to Create an Open Circuit Results: •...
  • Page 169 KENR9126 Troubleshooting Section E. Connect the P1 ECM connector. Connect the Results: connector for the exhaust gas temperature sensor. • OK – A 0535-3 diagnostic code was active before Expected Result: creating the short at the sensor connector. A 0535-4 diagnostic code became active after Each resistance measurement indicates an open creating the short at the sensor connector.

  • Page 170: Fuel Level - Test

    KENR9126 Troubleshooting Section b. Monitor the “Active Diagnostic Code” screen i04012478 on the electronic service tool. Wait at least 30 Fuel Level - Test seconds for activation of the code. A short circuit diagnostic code 0535-4 will be active for the exhaust gas temperature sensor. System Operation Description: c.
  • Page 171 KENR9126 Troubleshooting Section g02200933 Illustration 65 Schematic for the fuel level sensor Test Step 1. Inspect the Electrical Connectors and the Wiring A. Remove the electrical power from the ECM. B. Thoroughly inspect the J2/P2 ECM connectors. Refer to the diagnostic functional test Troubleshooting, “Electrical Connectors-Inspect”.
  • Page 172 KENR9126 Troubleshooting Section Results: Results: • OK – The connectors and the wiring appear to be • OK – The electronic service tool displays the OK. Proceed to Test Step 2. correct fuel level. • Not OK – There is a problem in the connectors Repair: The fuel level sensor appears to be and/or the wiring.

  • Page 173: Fuel Rail Pump Solenoid - Test

    KENR9126 Troubleshooting Section Test Step 5. Check the Sensor's i03460681 Resistance at the ECM Fuel Rail Pump Solenoid - Test A. Disconnect the J2/P2 connectors. Note: Be sure to wiggle the harness during the System Operation Description: following measurement in order to reveal an intermittent condition.
  • Page 174 KENR9126 Troubleshooting Section g01803553 Illustration 68 Typical schematic of the circuit for the fuel rail pump solenoid g01803554 Illustration 69 Typical view of the P2 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 175 KENR9126 Troubleshooting Section • Not OK – There is a fault with the connectors Expected Result: and/or the harness. The nominal resistance is less than 2 Ohms. Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Results: Ensure that all of the seals are correctly in place •...
  • Page 176 KENR9126 Troubleshooting Section Repair: Temporarily connect a new fuel rail pump If the diagnostic code has been cleared, then install to the harness, but do not install the fuel rail pump the new fuel rail pressure pump to the engine. to the engine.

  • Page 177: Ignition Keyswitch Circuit And Battery Supply Circuit - Test

    KENR9126 Troubleshooting Section Use the electronic service tool in order to clear all Results: logged diagnostic codes and then verify that the repair has eliminated the fault. • STOP. Repair: If the fault is eliminated with the test ECM, perform the following procedure: Test Step 7.
  • Page 178 KENR9126 Troubleshooting Section The cause of an intermittent power supply to the ECM can occur on either the positive side or on the negative side of the battery circuit. The connections for the unswitched battery+ may be routed through a dedicated protection device (circuit breaker).
  • Page 179 KENR9126 Troubleshooting Section g01803755 Illustration 70 Schematic for the ignition keyswitch and battery supply circuit g01803934 Illustration 71 Typical view of the pin locations on the P1 connector for the ignition keyswitch and battery supply circuit (1) Battery ground (GND) (8) Battery (+) (16) Battery ground (+) (2) Battery ground (GND)
  • Page 180 KENR9126 Troubleshooting Section Test Step 1. Inspect Electrical Connectors Test Step 2. Check for Active Diagnostic and Wiring Codes or Logged Diagnostic Codes A. Thoroughly inspect the P1 connector, the battery A. Connect the electronic service tool to the connections and the connections to the keyswitch. diagnostic connector.
  • Page 181 KENR9126 Troubleshooting Section E. Measure the voltage between P1:15 (Unswitched For intermittent faults such as intermittent Battery+) and P1:9 (Battery-). shutdowns that could be caused by the application wiring, temporarily bypassing the application wiring F. Measure the voltage between P1:16 (Unswitched may be an effective means of determining the root Battery+) and P1:10 (Battery-).
  • Page 182 KENR9126 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 183: Indicator Lamp Circuit - Test

    KENR9126 Troubleshooting Section Note: This bypass directly connects the circuit for the 6. If the fault returns with the suspect ECM, keyswitch to the ECM. The ECM will remain powered replace the ECM. until the connection to the unswitched battery+ line is disconnected.
  • Page 184 KENR9126 Troubleshooting Section g02186513 Illustration 73 Typical schematic of the indicator lamp circuit g02186514 Illustration 74 Typical example of the pin locations on the P1 connector (1) Ground (8) Battery+ (60) Warning lamp (2) Ground (15) Battery+ (61) Maintenance lamp (3) Ground (16) Battery+ (62) Low oil pressure lamp...
  • Page 185 KENR9126 Troubleshooting Section Results: C. Measure the voltage at the lamp socket. • OK – Proceed to Test Step 2. Expected Result: • Not OK The voltage should be between 12.0 Volts DC and 24.0 Volts DC. Repair: Repair the connectors or the harness or replace the connectors or the harness.

  • Page 186: Injector Data Incorrect - Test

    KENR9126 Troubleshooting Section Test Step 5. Check the Voltage at the ECM i04012451 Injector Data Incorrect - Test A. Disconnect the P1 connector. B. Temporarily disconnect the wire from the P1 connector that supplies the suspect lamp. System Operation Description: C.
  • Page 187 KENR9126 Troubleshooting Section • Use the electronic service tool in order to perform the 6-2 Cylinder #6 Injector erratic, intermittent, or “Fuel System Verification Test”. The “Fuel System incorrect Verification Test” is used to check that the system operates correctly after a repair has been made. Expected Result 2 On six cylinder engines, three injectors that share a common supply indicate a diagnostic code.

  • Page 188: Injector Solenoid Circuit - Test

    KENR9126 Troubleshooting Section • Use the electronic service tool in order to perform Not OK – The test ECM did not eliminate the fault. the “Fuel System Verification Test”. If the cylinders Carefully repeat this procedure from Test Step 1. indicate “PASS”, then the fault has been cleared.
  • Page 189 KENR9126 Troubleshooting Section “Injector Solenoid Test” Use the “Injector Solenoid Test” on the electronic service tool to aid in diagnosing an open circuit or a short circuit diagnostic code while the engine is not running. The “Injector Solenoid Test” will send a signal to each solenoid.
  • Page 190 KENR9126 Troubleshooting Section g01805334 Illustration 78 P2 pin connections for the engine (57) Injector Cylinder (Number 1) (59) Injector Cylinder (Number 3) (63) Injector Cylinder (Number 5) (35) Injector Cylinder (Number 1 Return) (33) Injector Cylinder (Number 3 Return) (7) Injector Cylinder (Number 5 Return) (58) Injector Cylinder (Number 2) (64) Injector Cylinder (Number 4) (62) Injector Cylinder (Number 6)
  • Page 191 KENR9126 Troubleshooting Section Test Step 1. Inspect Electrical Connectors C. Check for logged diagnostic codes that are related and Wiring to the injector solenoids on the electronic service tool. Expected Result: Electrical shock hazard. The electronic unit injec- One or more diagnostic codes that are related to the tor system uses 67-73 volts.
  • Page 192 KENR9126 Troubleshooting Section Note: Do not confuse the “Injector Solenoid Test” Note: The “Manual Cylinder Cutout Test” is also with the “Cylinder Cutout Test”. The “Cylinder Cutout available. Access the manual test by selecting the Test” is used to shut off fuel to a specific cylinder “Change”...
  • Page 193 KENR9126 Troubleshooting Section G. Repeat this test for each suspect injector. Stop Results: the “Injector Solenoid Test” before handling the jumper wires. • OK – There is a fault with the injector harness under the valve cover. Expected Result: Repair: Repair the injector harness or replace the The electronic service tool displays “Current Above injector harness under the valve cover.
  • Page 194 KENR9126 Troubleshooting Section Test Step 8. Check the Harness between Note: On four cylinder engines, shorting a shared the ECM and the Valve Cover Base for a supply will affect the status of two injectors. Ignore Short Circuit the status of the other injector that is on the shared supply.
  • Page 195 KENR9126 Troubleshooting Section Test Step 10. Check the Engine Harness Note: When the engine harness is disconnected, Under the Valve Cover for a Short Circuit all of the diagnostic codes for supply voltage to the sensors will be active. This is normal. Clear all of the logged diagnostic codes after completing this test step.

  • Page 196: Speed Control (Pwm) - Test

    KENR9126 Troubleshooting Section Test Step 11. Check for a Short Circuit in Use the electronic service tool to clear all logged the Return Wire diagnostic codes and then perform the “Injector Solenoid Test” in order to verify that the repair eliminates the fault.
  • Page 197 KENR9126 Troubleshooting Section A problem with the circuit for the synchronization switch may prevent the ECM from responding to a valid signal from the TPS. The following active diagnostic codes will also prevent the ECM from responding to the throttle input: •...
  • Page 198 KENR9126 Troubleshooting Section b. If the engine is equipped with multiple throttle position sensors, verify that the “Secondary Throttle Enable” parameter is programmed to “Enabled”. Expected Result: The “Secondary Throttle Enable” parameter is programmed correctly. Results: • OK – The “Secondary Throttle Enable” parameter is programmed correctly.
  • Page 199 KENR9126 Troubleshooting Section Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem. STOP. Test Step 3. Check for Supply Voltage at the Throttle Position Sensor A.
  • Page 200 KENR9126 Troubleshooting Section Expected Result: B. Connect a breakout T between the harness connectors (3 pin) for the throttle position sensor. Each resistance measurement indicates an open circuit. C. Connect a multimeter between terminals B and C on the breakout T. Results: D.

  • Page 201: Starting Aid (Glow Plug) Relay Circuit - Test

    KENR9126 Troubleshooting Section If the diagnostic code does not recur, the This glow plug start aid override test switches on the problem is resolved. Return the engine to cold starting aid when the engine is not running. The service. glow plug start aid override test aids the analysis of the circuit for the glow plug start aid relay.
  • Page 202 KENR9126 Troubleshooting Section g02192011 Illustration 85 Typical schematic for the starting aid switch g02192012 Illustration 86 Typical view of the pin locations on the P1 connector (1) Ground (GND) (10) Ground (GND) (32) Negative relay (2) Ground (GND) (25) Negative relay return (40) Keyswitch (3) Ground (GND) (26) Positive relay return...
  • Page 203 KENR9126 Troubleshooting Section Test Step 1. Inspect Electrical Connectors C. Use the electronic service tool to select the “Glow and Wiring Plug Override Test” in order to turn on the power for the glow plugs. A. Inspect the following connectors: D.
  • Page 204 KENR9126 Troubleshooting Section Results: The keyswitch is in the ON position. The measured voltage for the 12 Volt systems is a constant 10.5 • OK – The harness connects the ECM to the glow to 13.5 VDC. The measured voltage for the 24 Volt plug start aid relay and there are no shorts to other systems is a constant 21.0 to 27.0 VDC.

  • Page 205: Switch Circuits - Test

    KENR9126 Troubleshooting Section i04011089 Switch Circuits - Test System Operation Description: Switch circuits may have problems such as faulty wiring, faulty switches, or faulty connectors. Use the following diagnostic procedures in order to diagnose problems with these switch circuits and repair these switch circuits: •...
  • Page 206 KENR9126 Troubleshooting Section g02191993 Illustration 88 P1 terminals for the various switches (P1-1) “Negative Battery” (P1-50) “Trip clear switch” (P1-47) “Synchronize switch 1” (P1-52) “Remote shutdown switch” (P1-49) “Trolling mode switch” (P1-46) “Synchronize switch 2” (P1-51) “Maintenance clear switch” (P1-48) “Slow vessel mode switch” D.

  • Page 207: Throttle Position Sensor - Test

    KENR9126 Troubleshooting Section Test Step 2. Test the Switch for Proper If the switch does not operate correctly, there may Operation be a short circuit between the circuit for the suspect switch and another circuit. Carefully reinspect the A. Disconnect the P1 connector. components.
  • Page 208 KENR9126 Troubleshooting Section Test Step 3. Adjust the Throttle Linkage Expected Result: for the High Idle Position The throttle linkage is in good condition. The throttle moves without binding and without excessive drag. A. Place the throttle in the high idle position. Results: B.

  • Page 209: Transmission Oil Temperature - Test

    KENR9126 Troubleshooting Section i04012489 Transmission Oil Temperature - Test System Operation Description: Use this procedure to troubleshoot any suspect problems with the marine transmission oil temperature sensor. This procedure covers the following diagnostic codes: • 177-03 Transmission Oil Temperature open/short to +batt •...
  • Page 210 KENR9126 Troubleshooting Section g02191980 Illustration 91 P2 terminals that are associated with the marine transmission oil temperature sensor (P2-44) Return (P2-49) Marine transmission oil temperature Results: • OK – The connectors and wiring are OK. Proceed to Test Step 2. •...
  • Page 211 KENR9126 Troubleshooting Section Expected Result: C. Restore the electrical power to the ECM. Wait at least 30 seconds for activation of the diagnostic No diagnostic codes are active. codes. Results: D. Access the “Active Diagnostic Codes” screen on the electronic service tool and check for an active •...

  • Page 212: Wastegate Solenoid - Test

    KENR9126 Troubleshooting Section Results: Results: • OK – The engine harness and the ECM are OK. • OK – The ECM is working properly. The problem is in the wiring between the ECM and the harness Repair: Temporarily connect a new sensor to connector.
  • Page 213 KENR9126 Troubleshooting Section The required intake manifold pressure is calculated by the software that is contained in the Electronic Control Module (ECM). The ECM uses the wastegate regulator to control the wastegate in order to provide the precise value of intake manifold pressure. The wastegate regulator is controlled by a PWM signal from the ECM.
  • Page 214 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. Start the Perkins EST. D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes. Expected Result:...
  • Page 215 KENR9126 Troubleshooting Section • Results: “Low current” (open circuit) • Diagnostic codes 526-5 and/or 526-6 are active • “High current” (short circuit) and/or logged – Proceed to Test Step 2. Expected Result: • No Codes – The fault seems to be resolved. The electronic service tool displays no diagnostic Repair: For intermittent faults, refer to codes.
  • Page 216 KENR9126 Troubleshooting Section 2. Turn the keyswitch to the ON position. Access Repair: Perform the following procedure: the “Diagnostics Tests” on the electronic service tool. Activate the “Turbo Wastegate Solenoid 1. Make sure that the latest flash file for the Test”.
  • Page 217 KENR9126 Troubleshooting Section 2. If the fault is eliminated, reconnect the suspect 4. Use the electronic service tool to recheck the wastegate regulator. If the fault returns, system for active diagnostic codes. permanently install the replacement wastegate regulator. 5. If the fault is resolved with the test ECM, reconnect the suspect ECM.

  • Page 218: Index

    KENR9126 Index Section Index Numerics CID 0100 FMI 03 ........... 86 CID 0100 FMI 04 ........... 87 5 Volt Sensor Supply Circuit - Test ....... 115 CID 0100 FMI 10 ........... 87 CID 0110 FMI 03 ........... 87 CID 0110 FMI 04 ........... 88 CID 0127 FMI 03 ...........
  • Page 219 Electronic Service Tools ........12 Flash Programming a Flash File ......31 Optional Service Tools ........12 Fuel Dilution of Engine Oil ........59 Perkins Electronic Service Tool......13 Probable Causes ..........59 Required Service Tools ........12 Recommended Actions........59 Electronic Troubleshooting ........
  • Page 220 Wastegate Solenoid - Test........212 Probable Causes ..........65 Recommended Actions........66 Poor Acceleration or Response......66 Probable Causes ..........66 Recommended Actions........66 Programming Parameters ........30 Replacing the ECM..........17 ©2010 Perkins Engines Company Limited Printed in U.K. All Rights Reserved...

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