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Perkins 1104E Series Troubleshooting Manual

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RENR2696-01
March 2005
Troubleshooting
1104E and 1106E Engines
R F11 -U p ( Engine)
RH11-Up (Engine)
R K 11- U p ( Engine)
VK11-Up (Engine)

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Summary of Contents for Perkins 1104E Series

  • Page 1 RENR2696-01 March 2005 Troubleshooting 1104E and 1106E Engines R F11 -U p ( Engine) RH11-Up (Engine) R K 11- U p ( Engine) VK11-Up (Engine)
  • Page 2 Obtain the complete and most current information before you s t ar t any jo b . Perkins dea le rs 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

    RENR2696-01 Table of Contents Table of Contents CID 0091 FMI 02 Throttle Demand Sensor Erratic Or Intermittent ............64 CID 0091 FMI 03 Throttle Demand Sensor Open Circuit Or Shorted High ........65 Troubleshooting Section CID 0091 FMI 04 Throttle Demand Sensor Shorted Low ..............
  • Page 4 RENR2696-01 Table of Contents CID 1684 FMI 03 Fuel Injection Pump, Fuelling Engine Temperature Sensor Open or Short Circuit - Fault ..............77 Test ..............171 CID 1684 FMI 04 Fuel Injection Pump, Supply Fuel Injection Pump Circuit - Test ....... 178 Voltage Fault ............

  • Page 5: Troubleshooting Section

    RENR2696-01 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i01798100 System Overview System Operation The 1104 models RF, RH, RK and 1106 model VK engines were designed for electronic control. The engines include an Electronic Control Module (ECM), a fuel injection pump that is electronically controlled, and a collection of engine sensors.
  • Page 6 RENR2696-01 Troubleshooting Section Electronic Controls g00908788 Illustration 1...
  • Page 7 RENR2696-01 Troubleshooting Section g00954204 Illustration 2 The electronic system consists of the Electronic The governor compares the desired engine speed to Control Module (ECM), the engine sensors, and the the actual engine speed. The actual engine speed is Machine Interface Connector (MIC). The ECM is the determined through the crankshaft position sensor.
  • Page 8 Factory passwords are calculated Diagnostic Fault Codes on a computer system that is available only to Perkins distributors. Since factory passwords contain Diagnostic fault codes are provided in order to alphabetic characters, only an electronic service indicate that an electrical problem or an electronic tool may change System Configuration Parameters.

  • Page 9: Glossary

    DT, DT Connector, or Deutsch DT – This is a type Code – Refer to “Diagnostic Code” or “Event Code”. of connector that is used on Perkins engines. The connectors are manufactured by Deutsch. Cold Mode – Cold mode is a mode for cold starting and for cold engine operation that includes timing Duty Cycle –...
  • Page 10 RENR2696-01 Troubleshooting Section Electronic Control Module (ECM) – The ECM Harness – The harness is the bundle of wiring is the control computer of the engine. The ECM (loom) that connects all components of the electronic provides power to the electronics. The ECM monitors system.
  • Page 11 RENR2696-01 Troubleshooting Section Password – A password is a group of numeric Short Circuit – A short circuit is a condition that has characters or a group of alphanumeric characters an electrical circuit that is inadvertently connected to that is designed to restrict access to parameters. The an undesirable point.

  • Page 12: Electronic Service Tools

    RENR2696-01 Troubleshooting Section Table 1 i01798102 Electronic Service Tools Required Electronic Service Tools for the Use of the Electronic Service Tool Part Description Number Electronic Service Tools are designed to help the Required service technician with the diagnosis and repair of IBM compatible PC with electronic engines.

  • Page 13: Diagnostic Codes

    For authorization and ordering information, contact Perkins Help Desk - Irlam. If you are having problems with the software, you can contact the Perkins Service Systems Support Center. Optional Service Tools The following table contains service tools that may be helpful to service the engine.
  • Page 14 RENR2696-01 Troubleshooting Section Table 3 CID FMI Code J Code FMI Code Fault Description 0041 03 J0678 03 8V Sensor Power Supply, voltage more than normal 0041 04 J0678 04 8V Sensor Power Supply, voltage less than normal 0091 02 J0091 02 Throttle Demand Sensor, erratic or intermittent 0091 03...

  • Page 15: Indicator Lamps

    RENR2696-01 Troubleshooting Section (Table 3, contd) 1684 02 J1077 02 Fuel Injection Pump, software failure 1684 03 J1077 03 Fuel Injection Pump, fuelling fault 1684 04 J1077 04 Fuel Injection Pump, supply voltage fault 1684 05 J1077 05 Fuel Injection Pump, invalid pulse width 1684 07 J1077 07 Fuel Injection Pump, mechanical fault...
  • Page 16 RENR2696-01 Troubleshooting Section Use the lamps to check the engine’s Table 6 operational status or the existence Orange Red lamp Comments lamp (status) of any engine faults. (status) There are no apparent Each lamp will be illuminated in a combination of problems.
  • Page 17 RENR2696-01 Troubleshooting Section Table 8 Table 9 Orange Red lamp Comments Description Flash lamp (status) number code (status) 0041 8 Volt Power Supply No faults were detected. 0091 Throttle Position Sensor The oil pressure is low. 0100 Engine Oil Pressure Sensor Flashing Either the coolant temperature 0102...

  • Page 18: Replacing The Ecm

    RENR2696-01 Troubleshooting Section Each delay between each digit of the code will be Note: When a new ECM is not available, you may 2 seconds. need to remove an ECM from an engine that is not in service. The ECM must have the same serial number After one active code has been identified there will suffix.

  • Page 19: Self-Diagnostics

    RENR2696-01 Troubleshooting Section b. Check that the ECM mounting hardware is Diagnostic Code – When a problem with the installed correctly. The rubber grommets are electronic system is detected, the ECM generates a used to protect the ECM from excessive diagnostic code.

  • Page 20: Sensors And Electrical Connectors

    RENR2696-01 Troubleshooting Section i01798105 Sensors and Electrical Connectors g00954205 Illustration 5 1104 Typical example of left side sensor locations...
  • Page 21 RENR2696-01 Troubleshooting Section g00915379 Illustration 6 1104 engine Typical location of the VLPM g00882117 Illustration 7 1104 Typical example of right side sensor locations...
  • Page 22 RENR2696-01 Troubleshooting Section g00884570 Illustration 8 1106 Typical example of left side sensor locations...
  • Page 23 RENR2696-01 Troubleshooting Section g00908929 Illustration 9 1106 engine Typical location of the VLPM...
  • Page 24 RENR2696-01 Troubleshooting Section g00954214 Illustration 10 Typical example of right side sensor locations 1106...
  • Page 25 RENR2696-01 Troubleshooting Section Table 10 Connector Function J1/P1 ECM Connector 70 Pin Machine Harness J20/P20 Machine Interface Connector (70-Pin Engine Harness) J40/P40 Fuel Injection Pump (3-Pin Connector) J100/P100 Engine Coolant Temperature Sensor (2-Pin Connector) Intake Manifold Air Temperature J103/P103 Sensor (2-Pin Connector) J200/P200 Intake Manifold Pressure Sensor (3-Pin Connector)

  • Page 26: Engine Wiring Information

    RENR2696-01 Troubleshooting Section i02294251 Engine Wiring Information The wiring diagrams are revised periodically. The wiring diagrams will change with updates to the wiring harness. For the most current information, always check the revision number of the diagram. Use the diagram with the latest revision number. g01152042 Illustration 12 Schematic for the fuel injection pump and ECM power supply for engines with a Machine Interface Connector that has 70 pins...
  • Page 27 RENR2696-01 Troubleshooting Section g00955504 Illustration 13...
  • Page 28 RENR2696-01 Troubleshooting Section g00955499 Illustration 14...
  • Page 29 RENR2696-01 Troubleshooting Section g01152386 Illustration 15...
  • Page 30 RENR2696-01 Troubleshooting Section g01152104 Illustration 16...
  • Page 31 70 pins. Table 11 shows the conversion from engine models that have a connector with 70 pins to Perkins identifies all wires with eleven solid colors. engine models that have a connector with 31 pins. The circuit number is stamped on the wire at a 25 mm (1 inch) spacing.

  • Page 32: Programming Parameters

    Flash Programming In order to obtain the proper factory passwords, certain information must be given to an authorized Perkins distributor. Since the factory passwords contain alphabetic characters, the electronic service Flash Programming – This is a method of tool can be used to perform this function. In order...
  • Page 33 RENR2696-01 Troubleshooting Section Flash Programming a Personality Module 1. Connect the electronic service tool to the service tool connector. 2. Select “WinFlash” from the “Utilities” menu on the electronic service tool. “WinFlash” will try to detect an ECM. 3. When an ECM has been detected, the “ECM Selector”...

  • Page 34: System Configuration Parameters

    RENR2696-01 Troubleshooting Section System Configuration When an ECM is replaced this rating interlock code must match the code that is stored in the ECM. If the Parameters rating interlock code does not match the code that is stored in the ECM, both of the following situations will exist: i01798111 System Configuration...

  • Page 35: Troubleshooting Without A Diagnostic Code

    RENR2696-01 Troubleshooting Section Troubleshooting without a i01798098 Alternator Will Not Charge Diagnostic Code (Charging Problem) i01798099 Alternator Noise Note: This is NOT an electronic system problem. (Noisy Operation) Probable Causes • Alternator drive belts Note: This is NOT an electronic system problem. •...

  • Page 36: Can Not Reach Top Engine Rpm

    RENR2696-01 Troubleshooting Section Recommended Actions Recommended Actions Faulty Battery Diagnostic Codes 1. Verify that the battery is no longer able to hold a Check for active diagnostic codes on the electronic charge. Refer to Testing and Adjusting, “Battery service tool. Troubleshoot any active codes before - Test”.
  • Page 37 RENR2696-01 Troubleshooting Section • • Damage to the air intake and exhaust lines and Damaged cylinder head hoses Checking the Fuel Injection Nozzles 4. Make all necessary repairs to the engine. 1. Remove the fuel injection nozzles from the cylinder 5.

  • Page 38: Coolant In Engine Oil

    RENR2696-01 Troubleshooting Section 4. Use the electronic service tool to verify the 3. Remove the oil filter element or elements. Fit a maximum engine speed limit. new engine oil filter element or elements. Fill the crankcase with clean engine oil to the correct 5.

  • Page 39: Coolant Temperature Is Too High

    RENR2696-01 Troubleshooting Section 3. Check that the seating surfaces of the pressure i01798115 relief valve and the radiator cap are clean and Coolant Temperature Is Too undamaged. High Combustion Gases in the Cooling System Switch off the engine and allow the engine to cool Note: This is not an electronic system problem.

  • Page 40: Ecm Will Not Accept Factory Passwords

    RENR2696-01 Troubleshooting Section i02270218 i01798117 ECM Will Not Accept Factory ECM Will Not Communicate Passwords with Other Systems or Display Modules Probable Causes The connection of any electrical equipment and the disconnection of any electrical equipment may • cause an explosion hazard which may result in in- jury or death.

  • Page 41: Engine Cranks But Will Not Start

    RENR2696-01 Troubleshooting Section • The electrical power supply to the electronic i02270216 service tool Engine Cranks but Will Not Start • The engine protection device is disabling the power supply. • The electrical power supply to the ECM Probable Causes •...
  • Page 42 RENR2696-01 Troubleshooting Section Valve lash 3. If the crankshaft rotates freely proceed to “Starting Motor Solenoid or Starting Circuit”. 1. Check the valve lash and reset the valve lash if it 4. If the crankshaft does not rotate freely, check the is necessary.

  • Page 43: Engine Has Early Wear

    RENR2696-01 Troubleshooting Section Low Compression 11. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). 1. Remove the fuel injectors and perform a compression test. Refer to Systems Operations, 12. Check the fuel injection pump. Refer to Testing and Adjusting, “Compression - Test ”data.
  • Page 44 RENR2696-01 Troubleshooting Section Note: If the problem is intermittent and the problem 4. Check for air in the fuel system. Refer to Systems cannot be duplicated, refer to Troubleshooting, Operation, Testing and Adjusting, “Air in Fuel - “Intermittent Low Power or Power Cutout”. Test”.
  • Page 45 RENR2696-01 Troubleshooting Section Valve lash Check the Engine Speed/Timing Sensors 1. Check the valve lash and reset the valve lash if it Note: There are two engine speed/timing sensors. is necessary. Refer to Systems Operation, Testing One sensor is positioned in the cylinder block in order and Adjusting, “Engine Valve Lash - Inspect and to sense the crankshaft position and the crankshaft Adjust”.

  • Page 46: Engine Oil In Cooling System

    RENR2696-01 Troubleshooting Section 3. Refer to Troubleshooting, “Fuel Injection Pump 5. If any of the cylinder liner projections were Circuit - Test”. incorrect, and this had resulted in the failure of the head gasket, fit a new head gasket. Refer to Disassembly and Assembly, “Cylinder Head - i01798122 Install”...

  • Page 47: Engine Stalls At Low Rpm

    RENR2696-01 Troubleshooting Section Fuel Supply • 91-08 Throttle Position Sensor Abnormal • 774-08 Sec Throttle Position Signal Abnormal 1. Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, “Fuel System • 41-03 8 Volt Sensor Power Supply Voltage more Pressure - Test”.

  • Page 48: Engine Vibration

    RENR2696-01 Troubleshooting Section 3. If there is a reduction in engine speed proceed to i01798125 “Valve Lash”. Engine Vibration Valve Lash 1. Ensure that the valve lash is correct. Reset the Note: This is NOT an electronic system problem. valve lash if it is not correct. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Refer to Testing and Adjusting for information on Lash - Inspect and Adjust”.

  • Page 49: Engine Will Not Crank

    RENR2696-01 Troubleshooting Section 2. Check that the turbocharger drain is not blocked 3. If the 1639-09 diagnostic code is active the or restricted. machine security system is armed. Deactivate the machine security system and try to start the 3. Check that the turbocharger housing is free of dirt engine.

  • Page 50: Excessive Black Smoke

    RENR2696-01 Troubleshooting Section Individual Malfunctioning Cylinder • Seizure • Broken components 1. With the engine speed at a fast idle, loosen the high pressure fuel line to the fuel injection nozzle • Bent components of number 1 cylinder. Note if there is any reduction in engine speed.

  • Page 51: Excessive Engine Oil Consumption

    RENR2696-01 Troubleshooting Section Verifying the ECM Software 2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”. 1. Connect the electronic service tool to the 3. Ensure that the repairs have eliminated the diagnostic connector and check for the following problems.

  • Page 52: Excessive Valve Lash

    RENR2696-01 Troubleshooting Section 3. Check the air intake and the exhaust system for 1. Remove the fuel injection nozzles and perform a the following defects: compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data. • Blockages 2.

  • Page 53: Excessive White Smoke

    RENR2696-01 Troubleshooting Section Valve Lash • Engine pressure sensors Adjust the valve lash of the engine. Refer to Testing Recommended Actions and Adjusting, “Air Intake and Exhaust System” for the correct procedure. Fuel Supply Valve Train Components 1. Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, “Fuel System 1.

  • Page 54: Intake Air Temperature Is Too High

    RENR2696-01 Troubleshooting Section Valve Lash 4. If the problem has not been eliminated, proceed to “Coolant Temperature Sensor Circuit”. 1. Ensure that the valve lash is correct. Refer to Testing and Adjusting, “Engine Valve Lash - Coolant Temperature Sensor Circuit Inspect/Adjust”.

  • Page 55: Intermittent Engine Shutdown

    RENR2696-01 Troubleshooting Section Coolant Temperature • Check the pump for proper operation. • Refer to Troubleshooting, “Coolant Temperature Is Make repairs, if necessary. Too High”. Check for Sufficient Flow of Air Through Check for High Intake Air Restriction the Aftercooler (if equipped) and/or High Altitude Determine the pressure differential of the intake air When intake air pressure is low, the turbocharger...

  • Page 56: Intermittent Low Power Or Power Cutout

    RENR2696-01 Troubleshooting Section 4. Check for air in the fuel system. Refer to Systems 2. Refer to Troubleshooting, “Electrical Connectors Operation, Testing and Adjusting, “Air in Fuel - - Inspect”. Test”. 3. Use the electronic service tool to check for 5.
  • Page 57 RENR2696-01 Troubleshooting Section Diagnostic Codes Check the Intake Manifold Pressure Check for active diagnostic codes on the electronic 1. Use the electronic service tool to verify the intake service tool. Troubleshoot any active codes before manifold pressure. continuing with this procedure. 2.

  • Page 58: Low Engine Oil Pressure

    RENR2696-01 Troubleshooting Section • 4. Verify that the ECM connections for the power Piston cooling jets (if equipped) and ground connections at the fuel pump are • connected properly. Engine oil suction tube • 5. If a fault is suspected with the fuel injection Engine oil pump pump power and ground connections refer to •...

  • Page 59: Low Power/Poor Or No Response To Throttle

    RENR2696-01 Troubleshooting Section Bearing Clearance Fuel Supply Inspect the engine components for excessive bearing 1. Check the fuel pressure. Refer to Systems clearance. If necessary, replace the bearings and/or Operation, Testing and Adjusting, “Fuel System the components. The following list is an example Pressure - Test”.
  • Page 60 RENR2696-01 Troubleshooting Section Individual Malfunctioning Cylinders 2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”. 1. With the engine speed at a fast idle, loosen the high pressure fuel line to the fuel injection nozzle 3.

  • Page 61: Mechanical Noise (Knock) In Engine

    RENR2696-01 Troubleshooting Section Recommended Actions 4. Use the electronic service tool to verify the maximum engine speed limit. Accessory Equipment 5. Use the electronic service tool to reset the parameters to the OEM specifications. Isolate the source of the noise. Remove the suspect engine accessories.

  • Page 62: Poor Acceleration Or Response

    RENR2696-01 Troubleshooting Section Valve Lash 4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel - Refer to Troubleshooting, “Excessive Valve Lash”. Test”. 5. Check that the fuel lines are tight and secured i01798138 properly.
  • Page 63 RENR2696-01 Troubleshooting Section 4. If the repair does not eliminate the fault proceed to 6. Ensure that the wastegate on the turbocharger is “Check the Fuel Injection Nozzles”. adjusted correctly. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. Examples of low compression are shown in the The adjustment of the wastegate is set at the following list:...

  • Page 64: Troubleshooting With A Diagnostic Code

    RENR2696-01 Troubleshooting Section Troubleshooting with a • The ECM reads signal voltage that is below normal. Diagnostic Code System Response: The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. i01798139 CID 0041 FMI 03 8v Sensor The ECM will return the engine to idle or a safe Power Supply, Voltage More speed.

  • Page 65: Cid 0091 Fmi 03 Throttle Demand Sensor Open Circuit Or Shorted High

    RENR2696-01 Troubleshooting Section When a fault is detected and the engine is above the System Response: predetermined safe speed, the engine will reduce speed to the safe speed. The ECM will log the diagnostic code. The diagnostic codes may be viewed on the electronic service tool. When a fault is detected and the engine is below the predetermined safe speed, the engine will match the The ECM will return the engine to low idle or to the...

  • Page 66: Cid 0091 Fmi 08 Throttle Demand Sensor Abnormal Signal

    RENR2696-01 Troubleshooting Section • Results: A 5 volt failure • • OK – STOP. A 5 volt fault System Response: i01798144 CID 0091 FMI 08 Throttle The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. Demand Sensor Abnormal Signal The ECM will return the engine to the low idle or to...

  • Page 67: Cid 0100 Fmi 04 Engine Oil Pressure Sensor Shorted Low

    RENR2696-01 Troubleshooting Section The ECM will generate a CID 100 FMI 03 diagnostic i01877641 code on the Data Link. The diagnostic code will be CID 0100 FMI 10 Engine displayed on the diagnostic screen of the electronic Oil Pressure Sensor, Power service tool.

  • Page 68: Cid 0102 Fmi 04 Intake Manifold Pressure Sensor Shorted Low

    RENR2696-01 Troubleshooting Section • The ECM has been powered for at least fifteen System Response: seconds. The ECM will set intake manifold pressure to a • CID 262-03 5V Sensor Power Supply Voltage More default value. Than Normal and CID 262-04 5V Sensor Power Supply Voltage Less Than Normal are not active.

  • Page 69: Cid 0105 Fmi 03 Intake Manifold Temperature Sensor Open Circuit Or Shorted High

    RENR2696-01 Troubleshooting Section System Response: i01798151 CID 0105 FMI 04 Intake The ECM will log the diagnostic code. The diagnostic Manifold Temperature Sensor code may be viewed on the electronic service tool. The ECM will flag the intake manifold pressure as Shorted Low invalid data.

  • Page 70: Cid 0110 Fmi 04 Engine Coolant Temperature Sensor Shorted Low

    RENR2696-01 Troubleshooting Section • System Response: Reduced engine speed (rpm) • The ECM will log the diagnostic code. The diagnostic Poor cold starting code may be viewed on the electronic service tool. The ECM flags coolant temperature as invalid data Troubleshooting: and a default value is used.

  • Page 71: Cid 0247 Fmi 09 J1939 Datalink, Abnormal Update

    RENR2696-01 Troubleshooting Section Troubleshooting: Note: The personality module is a flash personality module. The personality module is installed into the Further troubleshooting is required. ECM by flash programming. Perform the following diagnostic procedure: “Fuel System Response: Injection Pump Circuit - Test” The ECM will not log any diagnostic code except Results: diagnostic code 0253.

  • Page 72: Cid 0262 Fmi 04 5V Sensor Power Supply, Voltage Less Than Normal

    RENR2696-01 Troubleshooting Section • The ECM has been powered for at least three Troubleshooting: seconds. Further troubleshooting is required. System Response: Perform the following diagnostic procedure: “5 Volt The ECM will log the diagnostic code. The diagnostic Pressure Sensor Circuit - Test” code may be viewed on the electronic service tool.

  • Page 73: Cid 0320 Fmi 02 Speed And Timing Sensor Intermittent Loss Of Signal

    RENR2696-01 Troubleshooting Section System Response: i01798159 CID 0320 FMI 02 Speed And The Electronic Control Module (ECM) will use the Timing Sensor Intermittent speed/timing sensor in the fuel injection pump to determine engine speed. The ECM will log the Loss Of Signal diagnostic code.

  • Page 74: Cid 0774 Fmi 02 Throttle Demand Sensor No.2 Erratic Or Intermittent

    RENR2696-01 Troubleshooting Section System Response: Possible Performance Effect: The Electronic Control Module (ECM) will log the The engine speed defaults to low idle or a diagnostic code. The ECM will force the engine to a predetermined safe speed. default value or a safe speed. The diagnostic code may be viewed on the electronic service tool.

  • Page 75: Cid 0774 Fmi 04 Throttle Demand Sensor No.2 Shorted Low

    RENR2696-01 Troubleshooting Section The ECM will return the engine to low idle or to a safe i01798165 speed while the diagnostic code is active. CID 0774 FMI 08 Throttle Demand Sensor No.2 Possible Performance Effect: Abnormal Signal • Low power •...

  • Page 76: Cid 1627 Fmi 03 Fuel Injection Pump Relay Did Not Turn Off

    The fuel temperature may be above the recommended maximum operating temperature. • Low power The Perkins recommended maximum operating fuel temperature is 70 °C (158.0 °F) at the inlet to the fuel • Reduced engine speed injection pump. The electronic fuel injection pump will note that the fuel temperature is too high.

  • Page 77: Cid 1684 Fmi 02 Fuel Injection Pump, Software Failure

    Troubleshooting: If the problem still exists contact the Perkins Technical Support Centre in order to change the fuel injection Contact the Perkins Technical Support Centre in pump. The warranty of the fuel injection pump will order to check if the software version is correct.

  • Page 78: Cid 1684 Fmi 05 Fuel Injection Pump, Invalid Pulse Width

    System Response: replace the suspect ECM. Possible Performance Effect: B. If the ECM is OK, contact the Perkins Technical Support Centre in order to change the fuel The diagnostic code is logged, but there will be no injection pump. The warranty of the fuel injection other system response.

  • Page 79: Cid 1684 Fmi 08 Fuel Injection Pump, Crankshaft Reference Fault

    RENR2696-01 Troubleshooting Section Test Step 2. Results: • OK – STOP. Perform the following diagnostic procedure: “Engine Speed/Timing Sensor Circuit - Test” i01798173 Results: CID 1684 FMI 08 Fuel Injection • OK – STOP. Pump, Crankshaft Reference • Fault Not OK – Proceed to Test Step 3. Test Step 3.

  • Page 80: Cid 1684 Fmi 09 Fuel Injection Pump, Can Fault

    RENR2696-01 Troubleshooting Section If the fault is still active, contact the Perkins Technical i01798174 Support Centre in order to change the fuel injection CID 1684 FMI 09 Fuel Injection pump. The warranty of the fuel injection pump will Pump, CAN Fault be affected if the pump is replaced without prior consultation.

  • Page 81: Cid 1684 Fmi 11 Fuel Injection Pump, Internal Sensor Fault

    Test Step 3. • OK – Proceed to Test Step 2. Contact the Perkins Technical Support Centre in order to change the fuel injection pump. The warranty Test Step 2. of the fuel injection pump will be affected if the pump is replaced without prior consultation.

  • Page 82: Cid 1684 Fmi 14 Fuel Injection Pump, No Communications

    Also check that there have been no software updates. Results: If the problem still exists contact the Perkins Technical • OK – STOP. Support Centre in order to change the fuel injection pump.

  • Page 83: Cid 1743 Fmi 02 Engine Speed Mode Selection Switch State, Invalid State

    RENR2696-01 Troubleshooting Section • Results: Incorrect data • OK – STOP. System Response: The engine speed fails to disengage from the set i01798179 speed. CID 1743 FMI 02 Engine Speed The ECM will log the diagnostic code. The diagnostic Mode Selection Switch State, code may be viewed on the electronic service tool.
  • Page 84 RENR2696-01 Troubleshooting Section Results: • OK – STOP.

  • Page 85: Troubleshooting With An Event Code

    RENR2696-01 Troubleshooting Section Troubleshooting with an Results: Event Code • OK – STOP. i01897925 i01798182 E016 High Engine Coolant Event Codes Temperature Shutdown Note: If a diagnostic code has already been logged then any associated event code to that fault will not Conditions Which Generate This Code: be logged as well.

  • Page 86: E025 High Intake Air Temperature Derate

    RENR2696-01 Troubleshooting Section • Troubleshooting: The intake manifold air temperature is greater than 76 °C (168 °F) for the 1106 engine. Refer to Troubleshooting, “Coolant Temperature Is • Too High”. The intake manifold air temperature is greater than 135 °C (275 °F) for the 1104 turbocharged engine. Results: •...

  • Page 87: E054 High Fuel Temperature Derate

    RENR2696-01 Troubleshooting Section • The engine has been running for at least 5 Troubleshooting: seconds. • There may be a problem with the fuel system. • The engine speed is above 350 RPM. • There may be a problem with the fuel temperature •...

  • Page 88: E056 High Fuel Temperature Warning

    RENR2696-01 Troubleshooting Section • Ensure that the repair eliminates the problem. Not OK STOP. Repair: Repair the diagnostic codes that are present. Refer to the appropriate topic in the “Troubleshooting With a Diagnostic Code” section i01798189 of this manual. E056 High Fuel Temperature Ensure that the repair eliminates the problem.

  • Page 89: E100 Low Engine Oil Pressure Warning

    RENR2696-01 Troubleshooting Section System Response: i01983749 E100 Low Engine Oil Pressure The ECM will log the event. The ECM will reset the Warning warning when the oil pressure rises 21 kPa (3 psi) above the threshold for at least four seconds. Possible Performance Effect: Conditions Which Generate This Code: •...

  • Page 90: E190 Engine Overspeed Warning

    RENR2696-01 Troubleshooting Section Results: Expected Result: • OK – There are no problems with engine oil Results: pressure. There may be an intermittent problem. • OK – STOP. Repair: Monitor the operation of the engine. Repair the problem. Ensure that the repair eliminates the i01798192 problem.

  • Page 91: E883 Engine Failed To Stop When Fuel Solenoid Disengaged

    RENR2696-01 Troubleshooting Section Test Step 2. Connect a test ECM to the engine in order to determine if the original ECM is causing the problem. Perform the following diagnostic procedure: “CAN Data Link Circuit - Test” Note: The parameters of the test ECM must match the parameters in the suspect ECM.

  • Page 92: Diagnostic Functional Tests

    RENR2696-01 Troubleshooting Section Diagnostic Functional Tests i01798194 5 Volt Engine Pressure Sensor Supply Circuit - Test System Operation Description: Use this procedure under the following situation: Use this procedure if another procedure has directed you here. Also use this procedure if any of the following diagnostic codes are active: •...
  • Page 93 RENR2696-01 Troubleshooting Section g00884730 Illustration 19 The sensor for the intake manifold pressure g00835146 Illustration 20 Engine oil pressure sensor...
  • Page 94 RENR2696-01 Troubleshooting Section g00954290 Illustration 21 Schematic of the +5 V supply for the engine pressure sensors Test Step 1. Inspect Electrical Connectors And Wiring. A. Thoroughly inspect the following connections: • P1/J1 ECM Engine harness connector • P20/J20 MIC Machine harness connector •...
  • Page 95 RENR2696-01 Troubleshooting Section g00954709 Illustration 22 B. Perform a 45 N (10 lb) pull test on each of the Repair: Repair the connectors or wiring and/or wires in the ECM connector that are associated replace the connectors or wiring. Ensure that all of with the +5 V sensor supply: the seals are properly in place and ensure that the connectors are completely coupled.
  • Page 96 RENR2696-01 Troubleshooting Section • 262-04 5 Volt Sensor Power Supply, voltage less than normal Results: • Active – Proceed to Test Step 3. • Logged ONLY – Proceed to Test Step 5. • Not Active or Logged – The +5 V supply is operating correctly at this time.
  • Page 97 RENR2696-01 Troubleshooting Section g00954711 Illustration 23 C. Refer to Troubleshooting, “Engine Wiring • 262-04 5 Volt Sensor Supply voltage less than Information” for wiring instructions. normal D. Disconnect J1/P1 ECM engine harness connector Note: When ECM engine harness connector J1/P1 is disconnected and the keyswitch is in the ON position, open circuit diagnostic codes will be “Active”...
  • Page 98 RENR2696-01 Troubleshooting Section • No – The +5 V sensor diagnostic code is no longer Repair: Reconnect the sensor that is suspected active when the harness is disconnected. Either of causing the problem. If the problem returns the harness or a sensor that is attached to the after the reconnection of the sensor, disconnect harness is causing the problem.

  • Page 99: Air Inlet Heater Circuit - Test

    RENR2696-01 Troubleshooting Section Test Step 5. Check the Engine Harness. g00954709 Illustration 24 A. Turn the keyswitch to the OFF position while the Results: engine is OFF. • OK – The +5 V line is not shorted in the engine B.
  • Page 100 RENR2696-01 Troubleshooting Section • Check the operation of the air inlet heater starting aid. Also use this procedure if another procedure has directed you here. The air inlet heater starting aid is used to improve the engines’ ability to start when the engine is cold. A reduction of white smoke is also a benefit of the air inlet heater starting aid.
  • Page 101 RENR2696-01 Troubleshooting Section g00878757 Illustration 26 ECM pin locations for air inlet heater starting aid g00954741 Illustration 27 MIC pin locations for the air inlet heater starting aid...
  • Page 102 RENR2696-01 Troubleshooting Section Test Step 1. Inspect Electrical Connectors Expected Result: and Wiring The battery voltage is correct. A. Thoroughly inspect the J1/P1 ECM connector and J20/P20 MIC. Inspect the terminal connections on Results: the air inlet heater relay. Refer to Troubleshooting, •...
  • Page 103 RENR2696-01 Troubleshooting Section E. Use the override setting in the electronic service Repair: Repair the damaged wire or replace the tool in order to engage the air inlet heater starting wire. Verify that the problem has been eliminated. aid. If the repair has not eliminated the problem F.

  • Page 104: Analog Throttle Position Sensor Circuit - Test

    RENR2696-01 Troubleshooting Section The system will check the switch position in relation i02270219 to the throttle position signal when the idle validation Analog Throttle Position has been set for use. If the switch position and the Sensor Circuit - Test signal from the throttle demand sensor are valid then the throttle will operate as normal.
  • Page 105 RENR2696-01 Troubleshooting Section g00955292 Illustration 28 Schematic of the analog throttle demand sensor g00997597 Illustration 29 ECM pin locations Test Step 1. Check for Connector C. Refer to Troubleshooting, “Electrical Connectors Damage. - Inspect”. A. Turn the keyswitch to the OFF position. D.
  • Page 106 RENR2696-01 Troubleshooting Section • P1:18 Throttle No 2 RESULT 3 The electronic service tool displays the following active diagnostic codes: • P1:25 Throttle No 1 • 91-02 • P1:44 Sensor common • 774-02 • P1:45 +5V DC sensor supply RESULT 4 The electronic service tool displays no E.
  • Page 107 RENR2696-01 Troubleshooting Section Test Step 4. Check the Voltage at the Throttle Demand Sensor. g00835148 Illustration 30 Typical example of the throttle demand sensor for the 1106 and 1104 engines • A. Turn the keyswitch to the OFF position. 262-04 5 Volt Sensor Power Supply voltage less than normal B.
  • Page 108 RENR2696-01 Troubleshooting Section • The problem returns after the old throttle demand sensor has been reconnected. STOP. Test Step 6. Check the Throttle Selection Status with the Electronic Service Tool. A. Check the status of the throttle selection switch (if equipped). The throttle selection status can be observed on the status display screen of the electronic service tool.
  • Page 109 RENR2696-01 Troubleshooting Section Test Step 7. Disconnect the Supply Terminals of the Throttle Demand Sensor at the ECM. g01137361 Illustration 31 Connections for the ECM terminals A. Turn the keyswitch to the OFF position. 1. Temporarily connect a test ECM. B.
  • Page 110 RENR2696-01 Troubleshooting Section Test Step 8. Check the Position of Throttle Demand Sensor. A. Turn the keyswitch to the OFF position. B. Install a Breakout T with 3 terminals to the throttle demand sensor. C. Turn the keyswitch to the ON position. D.
  • Page 111 RENR2696-01 Troubleshooting Section Test Step 9. Check the Throttle Demand Sensor at the ECM. g00854873 Illustration 32 Connections of the ECM terminals A. Turn the keyswitch to the OFF position. Repair: Check for the correct supply voltage at the ECM. If the voltage is correct, then the ECM B.
  • Page 112 RENR2696-01 Troubleshooting Section Test Step 10. Remove the Throttle Demand Sensor from the Engine Speed Control Assembly. g00706977 Illustration 33 Accelerator pedal assembly A. Turn the keyswitch to the OFF position. F. Record the signal voltage of the throttle demand sensor with the sensor slot in the released B.

  • Page 113: Can Data Link Circuit - Test

    RENR2696-01 Troubleshooting Section The output from the throttle demand sensor is 4.5 Note: Do not attempt to repair the wire harness volts or more with the sensor slot in the advanced between the ECM and the fuel injection pump. If the position.
  • Page 114 RENR2696-01 Troubleshooting Section g00910876 Illustration 34 Schematic for the CAN Data Link and the fuel injection pump...
  • Page 115 RENR2696-01 Troubleshooting Section Test Step 1. Inspect Electrical Connectors and Wiring g00885803 Illustration 35 A. Turn the keyswitch to the OFF position. Results: • B. Check the connectors and wiring for the following OK – Proceed to Test Step 2. problems: damage, corrosion, abrasion, and •...
  • Page 116 RENR2696-01 Troubleshooting Section Pump Control Unit Connector for an Open Circuit g00910876 Illustration 36 Schematic of the CAN Data Link and the fuel injection pump...
  • Page 117 RENR2696-01 Troubleshooting Section g00885803 Illustration 37 A. Disconnect P1 from the ECM. Note: Do not disconnect P40 Fuel injection Pump Connector. Note: Do not disconnect P40 Fuel Injection Pump Connector. B. Measure the resistance between terminal P1:58 and terminal P1:40. B.

  • Page 118: Data Link Circuit - Test

    ECM. the same version of the software that is in the ECM. Contact the Perkins Technical Service Centre in STOP. order to confirm the correct version of the software. •...
  • Page 119 RENR2696-01 Troubleshooting Section Test Step 1. Inspect Electrical Connectors and Wiring. g00954759 Illustration 38 Schematic for the Data Link g00954765 Illustration 39 ECM pin locations...
  • Page 120 RENR2696-01 Troubleshooting Section g00954767 Illustration 40 MIC pin locations A. Thoroughly inspect the following electrical Results: connectors: • OK – Proceed to Test Step 2. • ECM connector J1/P1 • Not OK • Data Link connectors J60 and J20/P20 Repair: Perform the following repair: •...
  • Page 121 RENR2696-01 Troubleshooting Section Result 3 The engine cranks but the engine will not start regardless of the condition of the electronic service tool. Result 4 The engine will not crank regardless of the condition of the electronic service tool. Result 5 The engine starts but the electronic service tool does not power up.
  • Page 122 RENR2696-01 Troubleshooting Section g00954771 Illustration 41 D. Measure the voltage on P1 between sockets P1:56 (UNSWITCHED POSITIVE BATTERY) and P1:68 (NEGATIVE BATTERY). E. Measure the voltage on P1 between sockets P1:57 (UNSWITCHED POSITIVE BATTERY) and P1:69 (NEGATIVE BATTERY). F. Measure the voltage on P1 between sockets P1:70 (keyswitch) and P1:68 (NEGATIVE BATTERY).
  • Page 123 RENR2696-01 Troubleshooting Section Test Step 4. Check the Battery Voltage that is coming to the Data Link Connector. g00954774 Illustration 42 A. Turn the keyswitch to the ON position. B. Use a multimeter in order to measure the voltage between the pin A POSITIVE SWITCHED BATTERY and pin B for NEGATIVE BATTERY on the service tool connector.
  • Page 124 RENR2696-01 Troubleshooting Section Test Step 5. Connect the Electronic Service Tool directly to the ECM. g00954776 Illustration 43 Typical bypass harness g00954771 Illustration 44 Pin locations for the Breakout T...
  • Page 125 RENR2696-01 Troubleshooting Section Test Step 6. Change Electronic Service Tool Components. Batteries give off flammable fumes which can ex- A. If another electronic engine is available, connect plode. the electronic service tool to the other engine. Ensure that the same cables are used. To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.

  • Page 126: Digital Throttle Position Sensor Circuit - Test

    RENR2696-01 Troubleshooting Section Test Step 7. Connect an Electronic 6. If the problem returns with the suspect ECM, Service Tool and the ECM to another replace the suspect ECM. Battery. 7. Verify that the repair eliminates the problem. STOP. Batteries give off flammable fumes which can ex- plode.
  • Page 127 RENR2696-01 Troubleshooting Section g00872561 Illustration 45 Schematic of the throttle position sensor g00872608 Illustration 46 ECM pin locations Test Step 1. Check for Connector C. Refer to Troubleshooting, “Electrical Connectors Damage. - Inspect”. A. Turn the keyswitch to the OFF position. D.
  • Page 128 RENR2696-01 Troubleshooting Section Test Step 3. Check the Throttle Position • P1:17 with the Electronic Service Tool. • P1:44 A. Connect the electronic service tool to the service E. Check the ECM connector (Allen Head Screw) for tool connector. the proper torque of 6.0 N·m (55 lb in). B.
  • Page 129 RENR2696-01 Troubleshooting Section Test Step 4. Check the Voltage at the Throttle Position Sensor. g00835148 Illustration 47 Typical example of the throttle position sensor for the 1104 and 1106 engines • A. Turn the keyswitch to the OFF position. 41-04 8 Volt Sensor Power Supply, voltage less than normal B.
  • Page 130 RENR2696-01 Troubleshooting Section • The problem returns after the old throttle position sensor has been reconnected. STOP. Test Step 6. Check the Throttle Selection Status with the Electronic Service Tool. A. Check the status of the throttle selection switch (if equipped). The throttle selection status can be observed on the status display screen of the electronic service tool.
  • Page 131 RENR2696-01 Troubleshooting Section Test Step 7. Disconnect the Supply Terminals of the Throttle Position Sensor at the ECM. g01148457 Illustration 48 Connections for the ECM terminals A. Turn the keyswitch to the OFF position. Repair: Check the battery voltage for P1 between terminal 56 and terminal 57 to terminal 68 and B.
  • Page 132 RENR2696-01 Troubleshooting Section Repair: Connect the cables one at a time. Connect terminal 44 to the ECM. Check if the diagnostic code reappears. Then connect terminal 17 to the ECM. Use the electronic service tool to check if the diagnostic code reappears. Replace the faulty cable.
  • Page 133 RENR2696-01 Troubleshooting Section Test Step 9. Check the Throttle Position Sensor at the ECM. g00854873 Illustration 49 Connections of the ECM terminals A. Turn the keyswitch to the OFF position. Repair: Check for the proper supply voltage at the ECM. If the voltage is correct, then the ECM B.
  • Page 134 RENR2696-01 Troubleshooting Section Test Step 10. Remove the Throttle Position Sensor from the Engine Speed Control Assembly. g00706977 Illustration 50 Accelerator pedal assembly A. Turn the keyswitch to the OFF position. F. Record the output signal of the throttle position sensor with the sensor slot in the released B.

  • Page 135: Electrical Connectors - Inspect

    RENR2696-01 Troubleshooting Section • The throttle position sensor output is 90 percent or Bent terminals more. • Improperly crimped terminals Results: • Corrosion • • Improper harness routing Repair: The operation of the throttle position sensor is correct. The fault is caused by the foot The original source of the problem must then be pedal or the lever assembly.
  • Page 136 RENR2696-01 Troubleshooting Section g00954204 Illustration 51 Basic engine schematic g01149572 Illustration 52 “VP30” Fuel injection pump connector (1) Data link (4) + Battery (7) Unused (2) Unused (5) - Battery (8) Unused (3) Engine position (6) Fuel shutoff (9) Data link...
  • Page 137 RENR2696-01 Troubleshooting Section g00955137 Illustration 53 Each end of the Machine SAE J1939 data link must be terminated with a 120 ohm resistor.
  • Page 138 RENR2696-01 Troubleshooting Section g00863007 Illustration 54...
  • Page 139 RENR2696-01 Troubleshooting Section g00856894 Illustration 55 70 pin Machine Interface Connector. g01152393 Illustration 56 31 pin Machine Interface Connector.
  • Page 140 RENR2696-01 Troubleshooting Section g00854362 Illustration 57 Connector receptacles (Deutsch) and connector plugs (Deutsch) (1) Wedge (receptacle) (3) Terminal pin (5) Sealing plug (2) Wedge (plug) (4) Machined socket terminal g00835079 Illustration 58 3 pin Deutsch plug connector (A) +5 Volt (B) Sensor common (C) Signal...
  • Page 141 RENR2696-01 Troubleshooting Section g00835081 Illustration 59 2 pin Deutsch connector (1) Signal (2) Sensor common g00835090 Illustration 60 Deutsch data link connector (A) +Battery (D) DL+ (G) J1939 + (B) - Battery (E) DL- (H) Spare (C) J1939 shield (F) J1939 - (J) Spare...
  • Page 142 RENR2696-01 Troubleshooting Section g00640158 Illustration 61 Routing of the harness and insertion of the plug (1) Correctly routed harness (3) Incorrectly routed harness (2) Correctly inserted plug (4) Incorrectly inserted plug Test Step 1. Check the Locking of the Repair: Verify that the repair has eliminated the DT Connector (Deutsch) and Check the fault.
  • Page 143 RENR2696-01 Troubleshooting Section Repair: Tighten the Allen head screw to the proper Monitor the “Inactive Diagnostic Code” screen of torque. the electronic service tool while the diagnostic code remains active. Pull each of the harnesses Verify that the fault has been eliminated. and the connectors that connect to the component.
  • Page 144 RENR2696-01 Troubleshooting Section B. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also check all of the hold down clamps for the harness in order to verify that the harness is not compressed by the clamp.
  • Page 145 RENR2696-01 Troubleshooting Section Test Step 7. Inspect the Connector C. If moisture or corrosion is evident in the connector, Terminals. the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the source of the moisture entry is not A.

  • Page 146: Electrical Power Supply Circuit - Test

    RENR2696-01 Troubleshooting Section Test Step 8. Check Individual Pin Retention into the Socket. g00640220 Illustration 63 Pin retention of the connector (1) Contact point (2) Contact of the socket Note: This is especially important for intermittent i01798200 faults. Electrical Power Supply Circuit - Test A.
  • Page 147 RENR2696-01 Troubleshooting Section The ECM receives electrical power (battery voltage) through the wiring within the engine harness. The ECM input at connector P1:70 (keyswitch) receives battery voltage from the keyswitch when the keyswitch is in the ON position or the START position.
  • Page 148 RENR2696-01 Troubleshooting Section g00910876 Illustration 64 Schematic of the power supply for the fuel injection pump Expected Result: If the batteries are OK proceed to Test Step 2. Batteries give off flammable fumes which can ex- plode. Results: To avoid injury or death, do not strike a match, •...
  • Page 149 RENR2696-01 Troubleshooting Section Test Step 2. Inspect Electrical Connectors And Wiring. g00905719 Illustration 65 A. Thoroughly inspect the harness connector J1/P1. Results: Also inspect the connections for the battery • and the connections to the keyswitch. Refer to OK – Proceed to Test Step 3. Troubleshooting, “Electrical Connectors - Inspect”...
  • Page 150 RENR2696-01 Troubleshooting Section Test Step 3. Check the Battery Voltage at the ECM. g00955807 Illustration 66 Test points for the Breakout T. A. Disconnect engine harness connector P1 from Results: ECM connector J1 and insert a 70 Pin Breakout T. •...
  • Page 151 RENR2696-01 Troubleshooting Section g00954776 Illustration 67 Bypass harness Note: This bypass harness is only for test E. Replace the 20 Amp in-line fuse. Verify applications. This bypass harness may be left only that communication from the service tool is temporarily on the engine. The bypass harness established.

  • Page 152: Engine Oil Level Switch Circuit - Test

    RENR2696-01 Troubleshooting Section Repair: If the problem still exists, temporarily connect a test ECM. Remove all jumpers and replace all connectors. The test ECM must be programmed with the same parameters as the suspect ECM. Recheck the system for active diagnostic codes and repeat the Test Step.
  • Page 153 RENR2696-01 Troubleshooting Section Test Step 1. Check for Connector Results: Damage. • OK – The engine oil level is correct. Proceed to A. Turn the circuit breaker for the battery to the OFF test step 3. position. • Not OK – The engine oil level is not correct. B.
  • Page 154 RENR2696-01 Troubleshooting Section Expected Result: The electronic service tool should indicate “OK” when the wire short is installed. The electronic service tool should indicate “LOW” when the wire short is removed. Results: • OK – The electronic service tool screen indicates “OK”, when the wire short is in place.
  • Page 155 RENR2696-01 Troubleshooting Section A. Disconnect ECM connector J20/P20. B. Measure the resistance between P20:21 and P20:37. C. Measure the resistance between P20:21 and the engine ground. D. Measure the resistance between P20:37 and the engine ground. Expected Result: The resistance should be greater than 20,000 ohms. Results: •...
  • Page 156 RENR2696-01 Troubleshooting Section Results: • OK – The resistance is less than 10 ohms. Proceed to test step 7. • Not OK – The resistance is greater than 10 ohms. There is an open circuit or excessive resistance in the wiring harness. Repair: Repair the connectors or wiring and/or replace the connectors or wiring.

  • Page 157: Engine Pressure Sensor Open Or Short Circuit - Test

    RENR2696-01 Troubleshooting Section I. Turn the keyswitch to the ON position. The engine The troubleshooting procedures for the diagnostic should be OFF. codes of each pressure sensor are identical. The pressure sensors are sensors that have J. Observe the status of the “Engine Oil Level” on three terminals.
  • Page 158 RENR2696-01 Troubleshooting Section g00954290 Illustration 72 Schematic of pressure sensors Test Step 1. Check For Active +5 V Test Step 2. Verify All Active Diagnostic Sensor Supply Diagnostic Codes. Codes. A. Connect the electronic service tool to the A. Turn the keyswitch to the ON position. Wait at diagnostic connector.
  • Page 159 RENR2696-01 Troubleshooting Section Expected Result: One or more of the preceding diagnostic codes are active. Results: • Yes – Proceed to Test Step 3. • Repair: If the preceding codes are logged but not active and the engine is not running properly, refer to Troubleshooting, “Troubleshooting without a Diagnostic Code”.
  • Page 160 RENR2696-01 Troubleshooting Section C. Refer to Troubleshooting, “Electrical Connectors Results: - Inspect”. • SHORT Circuit – A short circuit diagnostic code is D. Perform a 45 N (10 lb) pull test on each of the active at this time. Proceed to Test Step 5. wires in the ECM connector and the sensor •...
  • Page 161 RENR2696-01 Troubleshooting Section Test Step 6. Measure the Sensor Supply Voltage. g00664397 Illustration 74 Test Step 7. Determine If The Short A. Turn the keyswitch to the OFF position. Circuit Is In The Connector Or In The Sensor. B. Disconnect the sensor from the engine harness. C.
  • Page 162 RENR2696-01 Troubleshooting Section Test Step 8. Create a Short Circuit Between the Signal and the Common Terminals at the Engine Harness Connector. g00664397 Illustration 75 Terminals for the pressure sensor connector A. Turn the keyswitch to the ON position. 2. Use the electronic service tool to verify if the diagnostic code remains active.
  • Page 163 RENR2696-01 Troubleshooting Section Test Step 9. Check the Operation of the ECM by Creating Open and Short Circuits at the ECM Connector. g00955141 Illustration 76 A. Turn the keyswitch to the OFF position. H. Install the jumper wire on the ECM connector J1. Insert the jumper wire between the terminal for the B.

  • Page 164: Engine Speed/Timing Sensor Circuit - Test

    RENR2696-01 Troubleshooting Section Note: The test ECM should have the same values Expected Result: and the same parameters as the suspect ECM. The diagnostic code disappears when the jumper or 2. Remove all jumpers and replace all connectors. the bypass is installed. 3.
  • Page 165 RENR2696-01 Troubleshooting Section The engine will start and the engine will run when only one sensor signal is present from either of the sensors. The loss of the signal from both of the sensors during engine operation will result in the termination of injection and the shutting down of the engine by the ECM.
  • Page 166 RENR2696-01 Troubleshooting Section Test Step 2. Check the Installation of the Engine Speed/Timing Sensors g00985468 Illustration 78 Speed/timing sensor • A. Turn the keyswitch to the OFF position. Ensure that the sensor is fully seated into the engine before tightening the bracket bolt. B.
  • Page 167 RENR2696-01 Troubleshooting Section Test Step 3. Measure the Sensor Resistance Through the Wiring Harness g00887704 Illustration 79 Test Step 4. Measure the Resistance of A. Turn the keyswitch to the OFF position. the Sensor B. Remove the P1 ECM connector. A.
  • Page 168 RENR2696-01 Troubleshooting Section Verify that the repair has eliminated the faults. STOP. • Not OK – The sensor resistance is out of the nominal range. Repair: Perform the following procedure in order to check and install the new sensor: 1. Before installing the new sensor, measure the resistance of the new sensor.
  • Page 169 RENR2696-01 Troubleshooting Section Test Step 5. Measure the Resistance of the Cables Between the Fuel Injection Pump and the ECM g00910876 Illustration 80 Schematic of the power supply for fuel injection pump g00835107 Illustration 81 Schematic for the speed/timing sensor...
  • Page 170 RENR2696-01 Troubleshooting Section g00885751 Illustration 82 Expected Result: The readings agree with the values that are listed above. Results: • OK – The ECM does not operate properly. Repair: Perform the following repairs on the suspect ECM. 1. Temporarily install a test ECM. Note: The test ECM should be programmed with the g00863550 Illustration 83...

  • Page 171: Engine Temperature Sensor Open Or Short Circuit - Test

    RENR2696-01 Troubleshooting Section Test Step 6. Check the Continuity of Note: The test ECM should be programmed with the the Cables From the ECM to the Fuel correct software. All parameters should be set to the Injection Pump same value as the suspect ECM. 2.
  • Page 172 RENR2696-01 Troubleshooting Section g00955142 Illustration 85 Schematic for engine temperature sensors g00835142 Illustration 86 Engine coolant temperature sensor and intake manifold air temperature sensor Test Step 1. Verify All Active Diagnostic • 105-03 Intake Manifold Temperature Sensor Codes. Open Circuit or Shorted High •...
  • Page 173 RENR2696-01 Troubleshooting Section Expected Result: One or more of the preceding diagnostic codes are active. Results: • Yes – Proceed to Test Step 2. • Repair: If the preceding codes are logged but not active and the engine is not running properly, refer to Troubleshooting, “Troubleshooting without a Diagnostic Code”.
  • Page 174 RENR2696-01 Troubleshooting Section E. Check the harness and wiring for abrasions and for pinch points from the sensor to the ECM. Expected Result: All connectors, pins, and sockets should be completely coupled and/or inserted. The harness and wiring should be free of corrosion, abrasion, and pinch points.
  • Page 175 RENR2696-01 Troubleshooting Section Test Step 4. Disconnect The Sensor In Order To Create An Open Circuit. g00835142 Illustration 88 Engine coolant temperature sensor A. Turn the keyswitch to the OFF position. Remove all inactive diagnostic fault codes. B. Disconnect the sensor connector of the sensor STOP.
  • Page 176 RENR2696-01 Troubleshooting Section Expected Result: A short circuit diagnostic code is active when the jumper is installed. An open circuit diagnostic code is active when the jumper is removed. Results: • OK – The engine harness and the ECM are OK. Repair: Perform the following repair: 1.
  • Page 177 RENR2696-01 Troubleshooting Section Test Step 6. Check The Operation Of The ECM By Creating An Open And A Short Circuit At The ECM Connector. g00955143 Illustration 89 A. Turn the keyswitch to the OFF position. H. Install the jumper on the engine harness connector.

  • Page 178: Fuel Injection Pump Circuit - Test

    RENR2696-01 Troubleshooting Section 2. Remove all jumpers and replace all connectors. 3. Verify that the repair eliminates the problem. 3. If the fault is eliminated with the test ECM, STOP. install the suspect ECM and verify that the fault • returns.
  • Page 179 RENR2696-01 Troubleshooting Section Note: The engine protection system (if equipped) and the engine shutdown system (if equipped) have the ability to disconnect the electrical power from the fuel injection pump. The engine protection system will disconnect the electrical power supply to the Electronic Control Module (ECM).
  • Page 180 RENR2696-01 Troubleshooting Section g00908788 Illustration 91 Schematic for the electronically controlled fuel system Test Step 1. Check the Batteries Repair: Recharge the batteries or replace the batteries. Verify that the repairs have eliminated A. Measure no-load battery voltage at the battery the problem.
  • Page 181 RENR2696-01 Troubleshooting Section Test Step 2. Inspect the Electrical Connectors and Wiring g00856174 Illustration 92 Connections in the machine interface connector for the fuel injection pump g00908748 Illustration 93 P40/J40 Fuel injection pump connector and the VLPM...
  • Page 182 RENR2696-01 Troubleshooting Section A. Thoroughly inspect the following terminal connections on the P40 Fuel Injection Pump Connector: • P40:6 - Pump Supply • P40:7 + Pump Supply Refer to Troubleshooting, “Electrical Connectors - Inspect”. B. Thoroughly inspect the following terminal connections on the P20/J20 Machine Interface Connector.
  • Page 183 RENR2696-01 Troubleshooting Section Test Step 3. Check the Supply Voltage at the Machine Interface Connector g00856527 Illustration 94 Breakout T g00856174 Illustration 95 Connections in the J20/P20 Machine Interface Connector for the fuel injection pump A. Disconnect the machine interface connector Results: P20 from ECM connector J1 and insert a 70 Pin •...
  • Page 184 Also check that there have been no Expected Result: software updates. If the problem still exists contact the Perkins Technical Support Centre in order to The measured voltage is between 11.0 VDC and 13.5 change the fuel injection pump. The warranty of VDC for a 12 volt system and between 22.0 VDC and...
  • Page 185 RENR2696-01 Troubleshooting Section • Intermittent voltage or the voltage is out of range Repair: There is a problem in the wiring between J20 connector and J40 connector. Repair the wiring or replace the wiring. Verify that the repair has eliminated the problem. STOP.
  • Page 186 RENR2696-01 Troubleshooting Section Repair: There is a problem with the wires between the battery and the fuel injection pump. Repair the wires or replace the wires. Verify that the repairs have eliminated the problem. STOP. Test Step 6. Check the Output of the Power Relay for the Fuel Injection Pump g00910876 Illustration 98...
  • Page 187 RENR2696-01 Troubleshooting Section Repair: There is a problem with the wiring between the fuel pump power relay and the machine interface connector P20. Repair the wiring or replace the wiring. Verify that the repair has eliminated the problem. STOP. • Not OK Repair: There is no voltage or the voltage is out of the acceptable range.
  • Page 188 RENR2696-01 Troubleshooting Section F. Check that there is no voltage with the keyswitch in the OFF position. Expected Result: The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system with no suspected intermittent problems at this time.
  • Page 189 RENR2696-01 Troubleshooting Section Test Step 8. Check the Output of the ECM Fuel Pump Power Control at the Machine Interface Connector g00910876 Illustration 100 Schematic for the fuel injection pump and the ECM power supply g00955177 Illustration 101 Breakout T A.
  • Page 190 RENR2696-01 Troubleshooting Section Expected Result: The measured voltage is between 11.0 VDC and 13.5 VDC for a 12 volt system and between 22.0 VDC and 27.0 VDC for a 24 volt system with no suspected intermittent problems at this time. Results: •...
  • Page 191 RENR2696-01 Troubleshooting Section g00955177 Illustration 103 Breakout T A. Turn the keyswitch to the OFF position. B. Disconnect P1 ECM connector. C. Connect a Breakout T between P1 ECM connector and J1. D. Measure the voltage between Test Point C relay coil and terminal 42 on the Breakout T.
  • Page 192 RENR2696-01 Troubleshooting Section Test Step 10. Measure the Voltage at the Pump Power Supply g00907932 Illustration 104 Connections for the J20/P20 machine interface connector and the power supply for the fuel injection pump...
  • Page 193 RENR2696-01 Troubleshooting Section g00907931 Illustration 105 Connections for the fuel injection pump control unit and VLPM Note: This test is designed to measure the resistance C. Connect a switch to P20:42 and P20:68. of the pump power supply by allowing a current to All connectors, pins, and sockets should be flow through the supply circuit and measuring the completely coupled and/or inserted.
  • Page 194 Also check that there have been no software updates. If the problem still exists contact the Perkins Tecnical Support Centre in order to change the fuel injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultation.

  • Page 195: Indicator Lamp Circuit - Test

    RENR2696-01 Troubleshooting Section Repair: Replace the voltage load protection module. The voltage load protection module should also be replaced when the fuel injection pump is replaced. STOP. i01798195 Indicator Lamp Circuit - Test System Operation Description: Use this procedure under the following circumstances: •...
  • Page 196 RENR2696-01 Troubleshooting Section g00954724 Illustration 108 Machine Interface Connector (MIC) pin locations for the indicator lamps. g00913254 Illustration 109 ECM pin locations for the indicator lamps...
  • Page 197 RENR2696-01 Troubleshooting Section Test Step 1. Inspect Electrical Connectors • Not OK and Wiring Repair: Replace the suspect component or repair A. Turn the keyswitch to the OFF position. the suspect component. Verify that the repairs have eliminated the problem. B.

  • Page 198: Mode Selection Circuit - Test

    RENR2696-01 Troubleshooting Section • Results: Check if the switch can be switched to ground. • • OK – The circuit for the diagnostic lamp is Check if the mode selector switch operates functioning properly. Proceed to Test Step 5. correctly. •...
  • Page 199 RENR2696-01 Troubleshooting Section Test Step 1. Inspect Electrical Connectors and Wiring g00955196 Illustration 110 Schematic for the mode selector switch g00878231 Illustration 111 ECM pin locations for the mode selector switch...
  • Page 200 RENR2696-01 Troubleshooting Section g00955199 Illustration 112 MIC pin locations for the mode selector switch A. Turn the keyswitch OFF. Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of B. Thoroughly inspect J1/P1 ECM connector, and the the seals are properly in place and ensure that the J20/P20 MIC.
  • Page 201 RENR2696-01 Troubleshooting Section Expected Result: The switch status should change as you cycle the mode switches. When the switch is in the OFF position the switch has an open condition. When the switch is in the ON position the switch has a closed condition.
  • Page 202 RENR2696-01 Troubleshooting Section E. Turn the keyswitch to the ON position. Monitor the status screen on the electronic service tool. Slowly connect and disconnect the jumper wire. Expected Result: When the jumper wire is disconnected the switch should be in the OPEN position. When the jumper wire is connected the switch should be in the CLOSED position.
  • Page 203 RENR2696-01 Troubleshooting Section • P20:21 Switch No. 2 • P20:9 Switch No. 3 Expected Result: The switch measures less than 10 ohms in the ON position. The switch measures more than 2000 ohms in the OFF position. Results: • OK – Proceed to Test Step 5. •...

  • Page 204: Set Speed Circuit - Test

    RENR2696-01 Troubleshooting Section • P1:21 Switch No. 2 With the switch in the ON position, the switch will have a closed condition. • P1:9 Switch No. 3 Results: D. Cycle the switch to the OFF position and to the • ON position.
  • Page 205 RENR2696-01 Troubleshooting Section The set speed switches are listed below: • P1:28 Set Speed Control ON or OFF • P1:11 Set Speed Continue or Accelerate • P1:19 Set Speed 1 or Set Speed 2 • P1:20 Set Speed Set or Decelerate •...
  • Page 206 RENR2696-01 Troubleshooting Section Test Step 2. Check “Set Speed Switch” When the set speed/decelerate switch is in the ON on the Electronic Service Tool position the set speed/decelerate switch should be in the CLOSED position. A. Turn the keyswitch to the OFF position. Result 4 When the set speed control resume or accelerate switch is in the OFF position the display B.
  • Page 207 RENR2696-01 Troubleshooting Section Test Step 3. Check the Status of the Automatic Set Speed Disengage Switch g00907849 Illustration 117 g00955250 Illustration 118 A. Disconnect the P20/J20 machine interface B. Insert a 70 pin Breakout T between the P20 and connector. J20.
  • Page 208 RENR2696-01 Troubleshooting Section C. Measure the resistance between the following pin locations: • P20:29 • P20:37 D. Use the electronic service tool to observe the voltage while the Automatic Set Speed Disengage Switch is operated OFF and ON. Expected Result: The electronic service tool will show that the status of the automatic set speed disengage switch is in the “ENGAGED”...
  • Page 209 RENR2696-01 Troubleshooting Section A. Turn the keyswitch to the OFF position. B. Remove the two wires from the P20:11 set speed control continue or accelerate switch. Use a suitable jumper in order to join the two wires together. C. Turn the keyswitch to the ON position. D.
  • Page 210 RENR2696-01 Troubleshooting Section Test Step 5. Measure the Resistance of the Cables at the Machine Interface Connector (MIC) g00955250 Illustration 120 A. Turn the keyswitch to the OFF position. The measured resistance should be more than 2000 ohms with the switch OFF. B.
  • Page 211 RENR2696-01 Troubleshooting Section Test Step 6. Measure the Resistance of the Cables at the ECM g00907849 Illustration 121 A. Turn the keyswitch to the OFF position. Results: • B. Reconnect the P20 MIC. OK – Proceed to Test Step 7. •...

  • Page 212: Throttle Switch Circuit - Test

    RENR2696-01 Troubleshooting Section E. Repeat this procedure for each of the following Also, use this procedure if another procedure has ECM pin connections: directed you here. • P1:11 Set speed control continue or accelerate The throttle switch provides the operator with the ability to select the desired engine speed.
  • Page 213 RENR2696-01 Troubleshooting Section g00905920 Illustration 122 Table 13 Correlation Between Throttle Switch Position and Status of the Throttle Inputs Status on the Electronic Service Tool Throttle Switch Position “Throttle Input #1” “Throttle Input #2” “Throttle Input #3” “Throttle Input #4” Test Step 1.
  • Page 214 RENR2696-01 Troubleshooting Section Results: Expected Result: • OK – Proceed to Test Step 2. The status of the suspect throttle input should be “OFF” when the jumper wire is disconnected. The • Not OK status should be “ON” when the jumper wire is connected.
  • Page 215 RENR2696-01 Troubleshooting Section Test Step 4. Check for Shorts in the Harness g00874926 Illustration 123 g00977350 Illustration 124 A. Turn the keyswitch to the OFF position. B. Disconnect J1/P1 ECM connector from the J20/P20 MIC.
  • Page 216 RENR2696-01 Troubleshooting Section C. Measure the resistance between the P1:37 switch return and the terminal for the suspect throttle input. D. Measure the resistance between the terminal for the suspect throttle input and the remaining terminals at the J20/P20 MIC: •...
  • Page 217 RENR2696-01 Troubleshooting Section Test Step 5. Check Resistance through the Harness g00874926 Illustration 125 g00977350 Illustration 126...
  • Page 218 RENR2696-01 Troubleshooting Section A. Use a suitable piece of wire to short P20:37 Switch Return to the terminal of the suspect throttle input at J20/P20 MIC. B. Measure the resistance between P20:37 (Digital Return) and the terminal for the suspect throttle input at ECM connector P1.
  • Page 219 RENR2696-01 Troubleshooting Section g00977350 Illustration 128 A. Turn the keyswitch to the OFF position. K. Observe the status of the suspect throttle input on the electronic service tool. B. Disconnect ECM connector J1/P1 and remove the wire for the suspect throttle input from ECM L.
  • Page 220 RENR2696-01 Troubleshooting Section Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, “Replacing the ECM” before replacing the ECM. STOP.

  • Page 221: Index

    RENR2696-01 Index Section Index Numerics CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low ..........69 5 Volt Engine Pressure Sensor Supply Circuit - CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit Or Shorted High ....69 Test ..............
  • Page 222 RENR2696-01 Index Section CID 1743 FMI 02 Engine Speed Mode Selection Engine Misfires, Runs Rough or Is Unstable..43 Switch State, Invalid State ........83 Probable Causes ..........44 CID 1894 FMI 02 Set Speed Control Disengage Recommended Actions........44 Switch State, Invalid State ........
  • Page 223 RENR2696-01 Index Section System Configuration Parameters......34 “ECM Software Release Date”......34 Important Safety Information ........2 “Engine Serial Number” ........34 Indicator Lamp Circuit - Test........ 195 “Full Load Setting”..........34 Indicator Lamps ............. 15 “Full Torque Setting”........... 34 Use the lamps to check the engine’s operational Rating Interlock ..........
  • Page 224 ©2005 Perkins Engines Company Limited A ll R i ght s R es er ve d Printed in U.K.

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