Perkins 1106C Troubleshooting Manual
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Perkins 1106C Troubleshooting Manual

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KENR6933-00
May 2007

Troubleshooting

1106C Genset
PK (Engine)

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Summary of Contents for Perkins 1106C

  • Page 1: Troubleshooting

    KENR6933-00 May 2007 Troubleshooting 1106C Genset PK (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

    KENR6933 Table of Contents Table of Contents Noise Coming from Cylinder ......... 68 Troubleshooting with a Diagnostic Code Diagnostic Code Cross Reference ....... 70 Troubleshooting Section No Diagnostic Codes Detected ......72 CID 0001 FMI 02 ..........72 Electronic Troubleshooting CID 0001 FMI 05 ..........
  • Page 4 KENR6933 Table of Contents CID 1834 FMI 02 ..........96 CID 2246 FMI 06 ..........96 Troubleshooting with an Event Code Event Codes ............97 E172 High Air Filter Restriction ......97 E232 High Fuel/Water Separator Water Level ..97 E360 Low Engine Oil Pressure ......

  • Page 5: Troubleshooting Section

    KENR6933 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i02755770 System Overview System Operation g01178531 Illustration 1 (1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor (2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped) (3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)

  • Page 6: Fuel Injection

    KENR6933 Troubleshooting Section • The 1106C Genset was designed for electronic Speed demand input control. The engine has an Electronic Control Module (ECM), a fuel rail pump and electronic unit injectors. At start-up, the ECM determines the top center All of these items are electronically controlled. There position of the number 1 cylinder from the secondary are also a number of engine sensors.

  • Page 7: Glossary

    Coolant Temperature Sensor – The coolant on a computer system that is available only to temperature sensor detects the engine coolant Perkins distributors. Since factory passwords contain temperature for all normal operating conditions and alphabetic characters, only an electronic service for engine monitoring.
  • Page 8 DT, DT Connector, or Deutsch DT – This is a type 1 – The data is valid but the data is below the normal of connector that is used on Perkins engines. The operational range. connectors are manufactured by Deutsch.
  • Page 9 KENR6933 Troubleshooting Section Full Load Setting (FLS) – The FLS is the parameter 9 – There has been an abnormal update. that represents the fuel system adjustment. This 10 – There is an abnormal rate of change. adjustment is made at the factory in order to fine tune the fuel system.
  • Page 10 KENR6933 Troubleshooting Section Primary Speed/Timing Sensor – This sensor Intake Manifold Air Temperature Sensor – The determines the position of the crankshaft during intake manifold air temperature sensor detects the air temperature in the intake manifold. The ECM engine operation. If the primary speed/timing monitors the air temperature and other data in the sensor fails during engine operation, the secondary intake manifold in order to adjust injection timing and...

  • Page 11: Electronic Service Tools

    Perkins electronic service tools are designed to help Tattletale – Certain parameters that affect the the service technician: operation of the engine are stored in the ECM.
  • Page 12 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...

  • Page 13: Indicator Lamps

    KENR6933 Troubleshooting Section Use the following procedure in order to connect Flashing – The lamp will be flashing when a derate the Electronic Service Tool and the Communication is active or when a derate is present because of Adapter II. an active diagnostic code.
  • Page 14 KENR6933 Troubleshooting Section Operation of the Indicator Lamps Table 4 Warning Shutdown Lamp State Description of the Indication Engine State Lamp Lamp (Alert (Action Lamp) Lamp) Lamp Check When the keyswitch is switched on, the lamps The keyswitch is on but the come on for a period of 2 seconds and the lamps engine has not yet been will then go off.
  • Page 15 KENR6933 Troubleshooting Section The sequence for the flash code is started by moving the keyswitch to “Off” and then moving the keyswitch to “On” twice within a period of three seconds. After a delay of 2 seconds, the “Shutdown” lamp will flash once for a period of half a second.

  • Page 16: Replacing The Ecm

    ECM. Program the parameters for the test the PTMI data on Perkins Secured Internet. ECM. The parameters must match the parameters in the suspect ECM. Refer to the following test steps 4.

  • Page 17: Self-Diagnostics

    KENR6933 Troubleshooting Section 8. If necessary, use the electronic service tool to clear Logged Code – Every generated code is stored the rating interlock. To clear the rating interlock, in the permanent memory of the ECM. The codes enter the factory password when the electronic are logged for 100 operating hours unless a code is service tool is first connected.
  • Page 18 KENR6933 Troubleshooting Section g01178874 Illustration 5 (1) Coolant Temperature Sensor (4) Fuel Rail Pressure Sensor (7) Primary Speed/Timing Sensor (2) Intake Manifold Temperature Sensor (5) Electronic Control Module (ECM) (8) Secondary Speed/Timing Sensor (3) Intake Manifold Pressure Sensor (6) Oil Pressure Sensor (9) Solenoid for the Fuel Rail Pump Note: If equipped, the wastegate regulator is installed on the right side of the engine.
  • Page 19 KENR6933 Troubleshooting Section g01178875 Illustration 6...
  • Page 20 KENR6933 Troubleshooting Section Table 5 Connector Function Machine Harness to ECM Connector (64 Pin Connector) Engine Harness to ECM Connector (64 Pin Connector) P532 Fuel Rail Pump Solenoid Connector (2 Pin Connector) P402 Secondary Speed/Timing Sensor (2 Pin Connector) P401 Primary Speed/Timing Sensor (2 Pin Connector) P201 Engine Oil Pressure Sensor (3 Pin Connector)

  • Page 21: Engine Wiring Information

    Blue Harness Wire Identification Brown Purple Gray Perkins identifies all wires with eleven solid colors. Orange White The circuit number is stamped on the wire at a 25 mm (1 inch) spacing. Table 6 lists the wire colors and the...
  • Page 22 KENR6933 Troubleshooting Section For example, a wire identification of F730-OR on the schematic would signify an orange wire with the circuit number F730. F730-OR identifies the power supply for the oil pressure sensor. Note: Always replace a harness wire with the same gauge of wire and with the same color code.
  • Page 23 KENR6933 Troubleshooting Section Schematic Diagrams g01213981 Illustration 8 Schematic Diagram for the Engine Harness...

  • Page 24: Ecm Harness Connector Terminals

    KENR6933 Troubleshooting Section g01224168 Illustration 9 Schematic Diagram for a Typical Application i02414687 ECM Harness Connector Terminals The Electronic Control Module (ECM) uses connectors that have 64 terminals to interface to the wiring harness. g01170706 Illustration 10 Layout of the Connector Pins (view from the rear)
  • Page 25 KENR6933 Troubleshooting Section Removal and Installation of the 3. Insert the removal tool into the hole that is adjacent to the terminal in order to release the Harness Connector Terminals locking device. Terminal Removal Note: Make sure that the tool stays perpendicular to the face of the connector.

  • Page 26: Programming Parameters

    KENR6933 Troubleshooting Section Programming Parameters Note: “Test ECM Mode” can only be activated if the engine serial number has not already been programmed during normal operation of the ECM. If the engine serial number is programmed and the i02415216 ECM is not in “Test ECM Mode”, the ECM can never Programming Parameters be used as a test ECM.
  • Page 27 KENR6933 Troubleshooting Section The ECM can store a maximum of two snapshots that are triggered by a diagnostic code. Two snapshots can be triggered manually. The snapshots are stored in a circular buffer. The newest snapshot will replace the oldest snapshot. The ECM stores the snapshots in memory.

  • Page 28: Factory Passwords

    • Program a new Electronic Control Module (ECM). Note: If you do not have the part number for the flash file, use “PTMI” on the Perkins Internet. When an ECM is replaced, the system configuration parameters must be programmed Note: You must have the engine serial number in into the new ECM.

  • Page 29: Injector Trim File

    If you receive any error messages during flash programming, click on the “Cancel” button in order • Select “Service Software Files” on the Perkins to stop the process. Access the information about Internet. the “ECM Summary” under the “Information” menu.

  • Page 30: Speed Demand Input Setup

    14. Repeat the procedure for each cylinder, as required. i02755771 Speed Demand Input Setup The 1106C Genset can have a digital input that uses a Pulse Width Modulated (PWM) signal, an analog input or an input that is provided through a communications port (J1939 Torque Speed Control g01224526 (TSC1)).
  • Page 31 KENR6933 Troubleshooting Section Upper Diagnostic Limit Initial Upper Position Limit This is the minimum throttle percentage that is This is the minimum throttle percentage that will detected by the ECM in normal operation when the be interpreted by the ECM as zero throttle. This pedal is in the maximum position.

  • Page 32: Customer Specified Parameters

    KENR6933 Troubleshooting Section Customer Specified Table 18 Parameters Minimum Maximum Default 1900 rpm 2900 rpm 2650 rpm i02517248 ECM Identification Parameter Customer Specified Parameters Equipment ID “Equipment ID” is the identification of the equipment that is assigned by the customer. The “Equipment Customer specified parameters allow the engine to ID”...
  • Page 33 KENR6933 Troubleshooting Section Limp Home Desired Engine Speed Table 21 Minimum Maximum Default The “Limp Home Desired Engine Speed” is the 0 rpm 3000 rpm 0 rpm maximum speed of the engine when the engine has been derated. Throttle Lock Increment Speed Ramp Table 26 Rate Minimum...
  • Page 34 KENR6933 Troubleshooting Section Air Filter Restriction Switch Installation Status An “Air Filter Restriction Switch” is an optional switch input. Programming the “Air Filter Restriction Switch Installation Status” parameter to “Enabled” notifies the ECM that an input from the air filter restriction switch is present on pin J1:47.

  • Page 35: Customer Specified Parameters Table

    KENR6933 Troubleshooting Section i02527577 Customer Specified Parameters Table Table 32 Customer Specified Parameters ECM Parameter Possible Values Default Value Engine Rating Parameter “Rating Number” 1 to 4 Low/High Idle Parameters “Low Idle Speed” 700 to 1200 rpm 750 rpm “High Idle Speed” 1900 to 2900 rpm 2650 rpm ECM Identification Parameter...

  • Page 36: Customer Specified Parameters Worksheet

    KENR6933 Troubleshooting Section i02444245 Customer Specified Parameters Worksheet Table 33 Customer Specified Parameters Worksheet Engine Rating Parameter “Rating Numbers” ECM Identifications Parameters “Equipment ID” Throttle Lock Parameters “Throttle Lock Feature Installation Status” “Throttle Lock Increment Speed Ramp Rate” “Throttle Lock Engine Set Speed Increment” Miscellaneous “Monitoring Mode Shutdowns”...

  • Page 37: System Configuration Parameters

    KENR6933 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: i02527574 pistons, fuel injectors, and other components.

  • Page 38: Troubleshooting Without A Diagnostic Code

    KENR6933 Troubleshooting Section Troubleshooting without a Alternator Drive Pulley Diagnostic Code Remove the nut for the alternator drive pulley and then inspect the nut and the drive shaft. If no damage is found, install the nut and tighten the nut to the correct torque.

  • Page 39: Battery

    KENR6933 Troubleshooting Section Alternator i02453228 Can Not Reach Top Engine Verify that the alternator is operating correctly. Refer to Testing and Adjusting, “Alternator - Test”. The alternator is not a serviceable item. The alternator must be replaced if the alternator is not operating correctly.
  • Page 40 KENR6933 Troubleshooting Section 7. If the repairs have not eliminated the faults 2. Check that the oil drain for the turbocharger is not proceed to “Throttle Signal for the Speed Demand blocked or restricted. Input”. 3. Check that the compressor housing for the turbocharger is free of dirt, debris and damage.

  • Page 41: Coolant In Engine Oil

    KENR6933 Troubleshooting Section Individual Malfunctioning Cylinders 9. Ensure that the fuel system has been primed. Refer to Testing and Adjusting, “Fuel System - Prime”. 1. With the engine speed at a fast idle, use the electronic service tool to isolate one cylinder at 10.

  • Page 42: Coolant Temperature Is Too High

    KENR6933 Troubleshooting Section Cylinder Block • Cylinder head • Cylinder block Inspect the top face of the cylinder block for faults and signs of leakage. If a fault is found, replace the cylinder block. If signs of leakage are found, Recommended Actions determine the cause of the leakage.

  • Page 43: Ecm Will Not Accept Factory Passwords

    KENR6933 Troubleshooting Section Coolant Level Coolant Pump 1. Inspect the coolant level. If necessary, add 1. Inspect the impeller of the coolant pump for coolant. damage and/or erosion. 2. Check the cooling system for leaks. Repair any 2. Make sure that the drive gear is not loose on the leaks immediately.

  • Page 44: Ecm Will Not Communicate With Other Systems Or Display Modules

    • Wiring to other control modules Note: The most commonly used port is “COM 1”. 3. Troubleshoot the Perkins Data Link for possible problems. Refer to Troubleshooting, “Data Link 4. Check for any hardware that is utilizing the Circuit - Test”.

  • Page 45: Engine Cranks But Will Not Start

    ECM will not communicate. 4. Attempt to start the engine. If the engine will not Perkins Data Link start, proceed to “Flash codes”. Troubleshoot the Perkins Data Link for possible Flash codes faults. Refer to Troubleshooting, “Data Link Circuit - Test”.
  • Page 46 KENR6933 Troubleshooting Section • 2. If any flash codes are displayed, diagnose the Restrictions flash codes and then rectify the faults. • Damage to lines or hoses 3. Attempt to start the engine. If the engine will not start, proceed to “Visible Faults”. 4.

  • Page 47: Electronic Control System

    KENR6933 Troubleshooting Section 6. Check for air in the fuel system. Refer to Testing d. If the signal from the secondary speed/timing and Adjusting, “Air in Fuel - Test”. sensor is greater than 0 rpm, connect a test ECM and then attempt to start the engine. If 7.

  • Page 48: Engine Has Early Wear

    KENR6933 Troubleshooting Section a. Check the leak off from the electronic unit 1. Check the operation of the glow plugs. Refer to injectors when the engine is cranked at an Systems Operation, Testing and Adjusting, “Glow engine speed that is greater than 150 rpm for Plugs - Test”.

  • Page 49: Engine Misfires, Runs Rough Or Is Unstable

    KENR6933 Troubleshooting Section Probable Causes Leaks in Air Intake System • Multiple starts or cold operation A leak in the air intake system may allow unfiltered air into the engine. Inspect the air intake system for • streaks which may indicate a leakage of unfiltered Incorrect maintenance intervals air.

  • Page 50: Glow Plugs

    Fuel Rail Pump Glow Plugs Note: The fuel rail pump that is installed by the factory on the 1106C Genset is a nonserviceable 1. Check for proper operation of the glow plugs. item. If any mechanical fault or any electrical fault Refer to Testing and Adjusting, “Glow Plugs -...

  • Page 51: Engine Oil In Cooling System

    KENR6933 Troubleshooting Section Low Compression (Cylinder Pressure) Electronic Unit Injectors 1. Perform a compression test. Refer to Testing and 1. With the engine speed at a fast idle, use the Adjusting, “Compression - Test ”. electronic service tool to isolate one cylinder at a time.

  • Page 52: Engine Vibration

    KENR6933 Troubleshooting Section 2. Check for leaks in the oil cooler assembly. Refer 3. Fill the cooling system. Refer to the Operation and to Testing and Adjusting, “Cooling System” for the Maintenance Manual, “Cooling System Coolant correct procedure. If a leak is found, install a new (ELC) - Change”.

  • Page 53: Engine Will Not Crank

    KENR6933 Troubleshooting Section Electronic Unit Injectors 2. Make all necessary repairs. Ensure that the repairs have eliminated the fault. If the vibration is still present proceed to “Low Compression 1. With the engine speed at a fast idle, use the (Cylinder Pressure)”.

  • Page 54: Excessive Black Smoke

    KENR6933 Troubleshooting Section Battery Cables and/or Batteries 5. Inspect the internal components for the following conditions: 1. Inspect the main power switch, battery posts, • and battery cables for loose connections and Seizure corrosion. If the battery cables are corroded, •...
  • Page 55 KENR6933 Troubleshooting Section • Check for the correct software 5. Check that the turbine blades rotate freely in the turbocharger. 2. Use the electronic service tool to verify any active diagnostic codes. 6. Ensure that the wastegate on the turbocharger is adjusted correctly.

  • Page 56: Excessive Engine Oil Consumption

    KENR6933 Troubleshooting Section Individual Malfunctioning Cylinder i02528860 Excessive Engine Oil 1. With the engine speed at a fast idle, use the Consumption electronic service tool to isolate one cylinder at a time. Note if there is any reduction in engine speed.

  • Page 57: Excessive Fuel Consumption

    KENR6933 Troubleshooting Section Oil Level Low Compression (cylinder pressure) 1. Check the oil level in the engine. 1. Perform a compression test. Refer to Testing and Adjusting, “Compression - Test ”. 2. If the oil level is high, check for contamination of the oil with coolant.

  • Page 58: Air Inlet And Exhaust System

    KENR6933 Troubleshooting Section Recommended Actions Low Engine Temperature 1. The operating temperature of the engine will affect Diagnostic Codes the rate of fuel consumption. Operation of the engine below the correct temperature will increase 1. Use the electronic service tool to check for any fuel consumption.

  • Page 59: Excessive Valve Lash

    KENR6933 Troubleshooting Section 1. Check the air intake system for leakage or 1. Use the electronic service tool to check for restrictions. Refer to Testing and Adjusting, “Air active diagnostic codes that relate to the primary Inlet and Exhaust System”. speed/timing sensor.

  • Page 60: Excessive White Smoke

    KENR6933 Troubleshooting Section Low Coolant Temperature 2. Check the components for the following conditions: abnormal wear, excessive wear, straightness, and cleanliness. If necessary, use new parts for Check that the water temperature regulator is replacement. operating correctly. Refer to Testing and Adjusting, “Water Temperature Regulator - Test”.

  • Page 61: Intake Air Temperature Is Too High

    Investigate engine is operating under load. For specific data, the cause of the fault on any cylinder that is refer to the Perkins Technical Marketing Information not operating. Investigate the cause of the fault for the engine.

  • Page 62: Intermittent Engine Shutdown

    KENR6933 Troubleshooting Section Insufficient Ambient Air Flow over the i02518234 Engine Intermittent Engine Shutdown 1. If equipped, check the condition of the cooling fan and the drive belt. Note: Use this procedure only if the engine shuts 2. If equipped, check that the cooling fan is operating down completely and the engine must be restarted.

  • Page 63: Intermittent Low Power Or Power Cutout

    KENR6933 Troubleshooting Section 4. Inspect the battery wires from the ECM to the i02535522 battery compartment. Refer to the Schematic Intermittent Low Power or Diagram. Inspect the wires and the power relay. Power Cutout Check the power and ground connections to the ECM.

  • Page 64: Low Engine Oil Pressure

    KENR6933 Troubleshooting Section 3. If a fault is suspected with the ECM power and 3. The intake manifold pressure should read ground connections refer to Troubleshooting, 0 ± 0.5 kPa (0 ± 0.07 psi). If the intake manifold “Electrical Power Supply Circuit - Test”. pressure is not within the limits, perform the following steps.

  • Page 65: Low Power/Poor Or No Response To Throttle

    KENR6933 Troubleshooting Section Oil Specification Engine Oil Suction Tube 1. Make sure that engine oil of the correct 1. Check the inlet screen on the oil suction tube specification is used. Refer to the Operation and remove any material that may be restricting and Maintenance Manual, “Refill Capacities and oil flow.
  • Page 66 KENR6933 Troubleshooting Section • Fuel supply 5. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load • Low compression (cylinder pressure) speed. • Individual malfunctioning cylinder 6. If the maximum no-load speed can not be obtained refer to Troubleshooting, “Throttle Switch Circuit •...
  • Page 67 KENR6933 Troubleshooting Section Low Compression (Cylinder Pressure) 3. Check that the compressor housing for the turbocharger is free of dirt and debris. 1. Perform a compression test. Refer to Testing and 4. Check that the turbine housing for the turbocharger Adjusting, “Compression - Test ”.

  • Page 68: Mechanical Noise (Knock) In Engine

    KENR6933 Troubleshooting Section 2. Remove the electronic unit injector from the 2. If the mechanical noise is still apparent, refer to suspect cylinder. Refer to Disassembly and “Pistons”. Assembly, “Electronic Unit Injector - Remove”. Pistons 3. Install a new electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit 1.
  • Page 69 KENR6933 Troubleshooting Section Pistons 1. Inspect the pistons for damage and wear. Replace any damaged parts. 2. If the noise is still apparent, refer to “Valve Lash”. Valve Lash 1. Refer to Troubleshooting, “Excessive Valve Lash”. 2. If the fault has not been eliminated, proceed to “Electronic Unit Injectors”.

  • Page 70: Troubleshooting With A Diagnostic Code

    KENR6933 Troubleshooting Section Troubleshooting with a Diagnostic Code i02444929 Diagnostic Code Cross Reference Table 34 3rd Party Device Flash CDL Code Description J1939 Code Code No Diagnostic Code Detected 0001-02 Cylinder #1 Injector Data Incorrect 651-2 0001-05 Cylinder #1 Injector open circuit 651-5 0001-06 Cylinder #1 Injector short...
  • Page 71 KENR6933 Troubleshooting Section (Table 34, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 0091-04 Accelerator pedal - voltage below normal 91-04 0091-08 Throttle Position signal abnormal 91-08 0100-03 Engine Oil Pressure open/short to +batt 100-03 0100-04 Engine Oil Pressure short to ground 100-04 0100-10 Engine Oil Pressure Sensor abnormal rate of change...

  • Page 72: No Diagnostic Codes Detected

    KENR6933 Troubleshooting Section (Table 34, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code E360-3 Low Oil Pressure - Shutdown 100-01 E361-1 High Engine Coolant Temperature - Warning 110-15 E361-2 110-16 High Engine Coolant Temperature - Derate E361-3 High Engine Coolant Temperature - Shutdown 110-00 E362-1...

  • Page 73: Cid 0001 Fmi 05

    KENR6933 Troubleshooting Section i02748533 i02748548 CID 0001 FMI 05 CID 0001 FMI 06 Conditions Which Generate This Code: Conditions Which Generate This Code: This diagnostic code is designed to indicate an open This diagnostic code is designed to indicate a short circuit (low current) in either the solenoid or the wiring circuit (high current) in either the solenoid or the for the electronic unit injector for No.

  • Page 74: Cid 0001 Fmi 07

    KENR6933 Troubleshooting Section • No 0262 diagnostic codes are active. i02748587 CID 0001 FMI 07 • Diagnostic code 0190-08 is not active. • No 0110 diagnostic codes are active. Conditions Which Generate This Code: System Response: The electronic unit injector is no longer capable of If equipped, the warning light will come on.

  • Page 75: Cid 0002 Fmi 06

    KENR6933 Troubleshooting Section An electrical fault can prevent the electronic unit The ECM will continue to attempt to operate the injector from operating. An open circuit in the wiring electronic unit injector after the diagnostic code that is unique to the electronic unit injector will prevent has been logged but a short circuit will prevent the that individual electronic unit injector from operating.

  • Page 76: Cid 0003 Fmi 05

    KENR6933 Troubleshooting Section • Data from the electronic unit injector for the No. 3 Possible Performance Effect: cylinder is out of limits. The engine will have low power and/or rough running. • Diagnostic code 0168-01 is not active. Troubleshooting: • Diagnostic codes 0001-05 and 0001-06 are not active.

  • Page 77: Cid 0003 Fmi 07

    KENR6933 Troubleshooting Section Troubleshooting: Results: • When an injector cutout test is performed, a faulty OK – STOP. electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors. i02655555 CID 0004 FMI 02 An electrical fault can prevent the electronic unit injector from operating.

  • Page 78: Cid 0004 Fmi 06

    KENR6933 Troubleshooting Section • The Electronic Control Module (ECM) detects the Battery voltage above 9 volts for 2 seconds following condition: System Response: • A low current condition (open circuit) for each of five consecutive attempts to operate If equipped, the warning light will come on. The ECM will log the diagnostic code.

  • Page 79: Cid 0005 Fmi 02

    KENR6933 Troubleshooting Section Troubleshooting: i02748722 CID 0005 FMI 05 Replace the suspect electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove” and Disassembly and Assembly, “Electronic Unit Injector - Install”. Conditions Which Generate This Code: Use the electronic service tool to perform the fuel This diagnostic code is designed to indicate an open system verification test.

  • Page 80: Cid 0005 Fmi 06

    KENR6933 Troubleshooting Section i02748725 i02752010 CID 0005 FMI 06 CID 0005 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) in either the solenoid or the delivering the correct amount of fuel.

  • Page 81: Cid 0006 Fmi 05

    KENR6933 Troubleshooting Section • No 0262 diagnostic codes are active. An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring • Diagnostic code 0190-08 is not active. that is unique to the electronic unit injector will prevent that individual electronic unit injector from operating.

  • Page 82: Cid 0006 Fmi 07

    KENR6933 Troubleshooting Section The ECM will continue to attempt to operate the i02752015 electronic unit injector after the diagnostic code CID 0041 FMI 03 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 83: Cid 0091 Fmi 03

    KENR6933 Troubleshooting Section • Diagnostic code 0168-01 is not active. Troubleshooting: System Response: Monitor the configuration screen on the electronic service tool in order to determine the type of speed The ECM will log the diagnostic code and the ECM demand circuit that is used on the engine.

  • Page 84: Cid 0091 Fmi 08

    KENR6933 Troubleshooting Section Troubleshooting: If equipped, the warning light will be on. The ECM will trigger a snapshot. The diagnostic code will be Monitor the configuration screen on the electronic logged if the engine is running. The diagnostic code service tool in order to determine the type of speed will not be logged if the engine is cranking.

  • Page 85: Cid 0100 Fmi 04

    KENR6933 Troubleshooting Section Troubleshooting: i02655616 CID 0100 FMI 10 This diagnostic code can be caused by an open circuit or a short to another power source. Perform the following diagnostic procedure: “Engine Conditions Which Generate This Code: Pressure Sensor Open or Short Circuit - Test” The Electronic Control Module (ECM) detects the Results: following conditions:...

  • Page 86: Cid 0110 Fmi 03

    KENR6933 Troubleshooting Section • The ECM has been powered for at least two i02655618 seconds. CID 0110 FMI 03 • Diagnostic code 0168-01 is not active. System Response: Conditions Which Generate This Code: The ECM will default to 90 °C (194 °F) for engine The Electronic Control Module (ECM) detects the coolant temperature.

  • Page 87: Cid 0168 Fmi 01

    KENR6933 Troubleshooting Section System Response: Troubleshooting: The ECM will log the diagnostic code. If equipped, Perform the following diagnostic procedure: “Ignition the warning lamp may come on. Keyswitch Circuit and Battery Supply Circuit - Test” Possible Performance Effect: Results: • None OK –...

  • Page 88: Cid 0172 Fmi 03

    KENR6933 Troubleshooting Section i02655634 i02655635 CID 0172 FMI 03 CID 0172 FMI 04 Conditions Which Generate This Code: Conditions Which Generate This Code: The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the following conditions: following conditions: •...

  • Page 89: Cid 0190 Fmi 08

    KENR6933 Troubleshooting Section Troubleshooting: i02493342 CID 0190 FMI 08 Perform the following diagnostic procedure: “CAN Data Link Circuit - Test” Results: Conditions Which Generate This Code: • OK – STOP. The Electronic Control Module (ECM) detects the following conditions: i02527036 •...

  • Page 90: Cid 0253 Fmi 02

    KENR6933 Troubleshooting Section System Response: i02527037 CID 0253 FMI 02 This code will not be logged. If equipped, the warning light will be on when this code is active. Possible Performance Effect: Conditions Which Generate This Code: The pressure in the fuel rail may be unstable and the The Electronic Control Module (ECM) detects engine may not run smoothly.

  • Page 91: Cid 0262 Fmi 04

    KENR6933 Troubleshooting Section System Response: i02656261 CID 0262 FMI 04 Note: The fault is not logged. The electronic service tool will display a list of the condition(s) on the “Active Diagnostics” screen that Conditions Which Generate This Code: must be resolved. If equipped, the warning light will come on.

  • Page 92: Cid 0526 Fmi 05

    KENR6933 Troubleshooting Section Possible Performance Effect: i02527044 CID 0526 FMI 06 The performance will not be affected unless both speed signals are lost. The loss of the signals from both speed/timing sensors will cause the ECM to shut down the engine. The engine will not restart if the Conditions Which Generate This Code: signal from the secondary speed/timing sensor is lost.

  • Page 93: Cid 1779 Fmi 05

    KENR6933 Troubleshooting Section • No 1785 diagnostic codes are active. Possible Performance Effect: • Diagnostic codes 0526-05 and 0526-06 are not An electrical fault may prevent the provision of active. pressure to the fuel rail. This may result in the loss of fuel injection.

  • Page 94: Cid 1785 Fmi 04

    KENR6933 Troubleshooting Section • • The signal voltage from the intake manifold No 0262 codes for the 5 volt supply are active. pressure sensor is above 4.95 VDC for at least • two seconds. The keyswitch is in the “ON” position so that the ECM is energized.

  • Page 95: Cid 1797 Fmi 03

    KENR6933 Troubleshooting Section System Response: Troubleshooting: If equipped, the warning light will be on. The ECM will This code can be caused by a loss of reference log the diagnostic code. The ECM will flag the intake ground, an open signal wire or a short to a voltage manifold pressure as being invalid.

  • Page 96: Cid 1834 Fmi 02

    KENR6933 Troubleshooting Section • There is a high current condition (short circuit) for i02527064 more than 2 seconds. CID 1834 FMI 02 System Response: The ECM will log the code. An ECM that was Conditions Which Generate This Code: previously blank will require a total of 2 hours of operation before the diagnostic code will be logged.

  • Page 97: Troubleshooting With An Event Code

    KENR6933 Troubleshooting Section Troubleshooting with an Results: Event Code • OK – STOP. i02536030 i02411237 E232 High Fuel/Water Event Codes Separator Water Level The ECM can log events. Events refer to engine operating conditions such as low oil pressure or high Conditions Which Generate This Code: coolant temperature.
  • Page 98 KENR6933 Troubleshooting Section • The engine has been running for at least ten seconds. • There are no active diagnostic codes for the oil pressure sensor or for the atmospheric pressure sensor. • Engine oil pressure is in the “LEVEL 1” area in Illustration 15 for eight seconds.

  • Page 99: E361 High Engine Coolant Temperature

    KENR6933 Troubleshooting Section The ECM will generate a 46 flash code that will be displayed via the diagnostic lamp. The ECM will generate a E360-3 event code. The ECM will generate a SPN 100-FMI 01 event code on the J1939 data link. The event code may be displayed on a receiving device on the J1939 data link.

  • Page 100: E362 Engine Overspeed

    E361-1 The event may be viewed by using a display module None or by using the Perkins Electronic Service Tool (EST). E361-2 The ECM will reset the event when the engine speed is lower than 2800 RPM for 0.6 seconds.

  • Page 101: E396 High Fuel Rail Pressure

    KENR6933 Troubleshooting Section i02493345 i02493479 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 a excessive fuel rail pressure. The ECM detects the problem with low fuel rail pressure.

  • Page 102: E539 High Intake Manifold Air Temperature

    KENR6933 Troubleshooting Section i02493480 E539 High Intake Manifold Air Temperature Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a problem with the engine’s intake manifold air temperature. The ECM detects the following problems: • The engine has been running for more than 3 minutes.

  • Page 103: E2143 Low Engine Coolant Level

    KENR6933 Troubleshooting Section i02539800 E2143 Low Engine Coolant Level Conditions Which Generate This Code: This event code will only be generated if a coolant level sensor has been properly installed and the customer programmable feature has been enabled. The Electronic Control Module (ECM) detects a problem with the engine coolant level.

  • Page 104: Diagnostic Functional Tests

    KENR6933 Troubleshooting Section Diagnostic Functional • A suspect sensor Tests • A suspect ECM i02656264 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 105 KENR6933 Troubleshooting Section Table 37 P2 Pin Connections Sensor Pin Function Fuel Rail Pressure Intake Manifold Oil Pressure Sensor Sensor Pressure Sensor Volts (5 Volts) Ground Signal Table 38 P1 OEM Connector Sensor Pin Function Analog Throttle Sensor 1 Analog Throttle Sensor 2 5 Volt Sensor Supply Ground...
  • Page 106 KENR6933 Troubleshooting Section g01173224 Illustration 19 Typical example of the fuel rail pressure sensor (1) Voltage supply (Vs) (2) Ground (GND) (3) Signal (SIG) g01173225 Illustration 20 Typical example of the intake manifold pressure sensor (1) Voltage Supply (Vs) (2) Ground (GND) (3) Signal (SIG) g01173226 Illustration 21...
  • Page 107 KENR6933 Troubleshooting Section g01173227 Illustration 22 Typical example of the P2 pressure sensor pin locations (38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5 Volts) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor Sensor Sensor (39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (5 Volts) Fuel Rail (40) Ground (GND) Fuel Rail Pressure Pressure Sensor...
  • Page 108 KENR6933 Troubleshooting Section g01246557 Illustration 24 Typical example of the schematic for the P1 OEM connections for the analog throttle demand sensors Test Step 1. Check for Connector Damage Expected Result: A. Turn the keyswitch to the OFF position. The connectors and the harness should be free of the following faults: damage, abrasion, corrosion, B.
  • Page 109 KENR6933 Troubleshooting Section Test Step 4. Install a New Sensor Expected Result: One of the following diagnostic codes is active: A. Remove the connector from the suspect sensor and connect the connector to a replacement • 0262-03 5 Volt Sensor DC Power Supply voltage sensor.
  • Page 110 KENR6933 Troubleshooting Section • Engine temperature sensors Results: • • Analog throttle demand sensors (if equipped) OK – The +5 Volt supply is within the expected range. Proceed to Test Step 7. Expected Result: • Not OK – The voltage is greater than 5.16 Volts Diagnostic code 0262-04 is not active.

  • Page 111: Can Data Link Circuit - Test

    KENR6933 Troubleshooting Section • Not OK – At least one intermittent fault was indicated. Repair: Repair the harness or the connector. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. STOP.
  • Page 112 KENR6933 Troubleshooting Section g01244083 Illustration 25 Typical example of the schematic for the CAN data link g01209013 Illustration 26 Typical view of the P1 connector pin locations (20) CAN- (21) CAN+ (22) CAN Shield Test Step 1. Inspect Electrical Connectors C.
  • Page 113 KENR6933 Troubleshooting Section Results: Measure the resistance of the two terminating resistors. • OK – Proceed to Test Step 2. If one of the terminating resistors is incorrect, • Not OK replace the faulty terminating resistor. Repair: Perform the following repair: If the two terminating resistors are between 50 and 70 Ohms, proceed to Test Step 4.

  • Page 114: Data Link Circuit - Test

    KENR6933 Troubleshooting Section Results: The electronic service tool may indicate the following error message: • OK – The other devices are operating correctly. Restart the diagnostic process. STOP. The version of the ECM is not recognized and the integrity of the changed parameters and displayed •...
  • Page 115 KENR6933 Troubleshooting Section g01244178 Illustration 27 Schematic of the diagnostic connector and the data link connector g01208535 Illustration 28 Typical view of the P2 pin locations for the diagnostic and data link connectors (20) Data link - (21) Data link +...
  • Page 116 KENR6933 Troubleshooting Section g01208545 Illustration 29 Typical view of the P1 pin locations for the diagnostic and data link connectors (23) Data link + (24) Data link - Test Step 1. Inspect Electrical Connectors Results: and Wiring • OK – Proceed to Test Step 2. A.
  • Page 117 KENR6933 Troubleshooting Section Results: Repair: Fabricate a jumper wire in order to connect pin “A” of the diagnostic connector to battery+ and • OK – The communications adapter is currently pin “B” to the battery-. receiving the correct voltage. Proceed to Test Step 2. Repair: If you are redirected to this step from Test Step 4.
  • Page 118 KENR6933 Troubleshooting Section H. Turn the keyswitch to the ON position. Results: • OK – The resistance is less than 10 Ohms. Expected Result: Proceed to Test Step 6. Result 1 The original electronic service tool works • Not OK – The resistance is greater than 10 Ohms. on another engine.
  • Page 119 KENR6933 Troubleshooting Section g01244183 Illustration 31 Schematic of the bypass harness connector...

  • Page 120: Ecm Memory - Test

    KENR6933 Troubleshooting Section g01184528 Illustration 32 Typical view of the P1 OEM connector pin locations 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 121: Electrical Connectors - Inspect

    KENR6933 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 122 KENR6933 Troubleshooting Section g01131276 g01131165 Illustration 34 Illustration 36 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 123 KENR6933 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 124 KENR6933 Troubleshooting Section Test Step 4. Perform a Pull Test on Each Test Step 5. Check Individual Pin Wire Terminal Connection Retention into the Socket g01237430 g01237435 Illustration 37 Illustration 38 A typical example of the lock wedge. Diagram for testing pin retention (1) Lock wedge A.

  • Page 125: Engine Pressure Sensor Open Or Short Circuit - Test

    OK – The connectors are in good repair. Proceed to Test Step 7. A. Select the “Wiggle Test” from the diagnostic tests on the Perkins Electronic Service Tool (EST). • Not OK – The connector’s locking mechanism is damaged or missing.
  • Page 126 KENR6933 Troubleshooting Section • 0100-10 Engine Oil Pressure Sensor abnormal rate of change • 1785-03 Intake Manifold Pressure Sensor voltage above normal • 1785-04 Intake Manifold Pressure Sensor voltage below normal • 1785-10 Intake Manifold Pressure Sensor abnormal rate of change •...
  • Page 127 KENR6933 Troubleshooting Section g01188154 Illustration 39 Typical example of the schematic for the sensors g01170309 g01170310 Illustration 40 Illustration 41 Fuel rail pressure sensor 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 128 KENR6933 Troubleshooting Section • 1797-03 Fuel Rail Pressure Sensor voltage above normal • 1797-04 Fuel Rail Pressure Sensor voltage below normal Expected Result: One or more of the preceding diagnostic codes are active. Results: • OK – Proceed to Test Step 2. g01170311 Illustration 42 •...
  • Page 129 KENR6933 Troubleshooting Section Test Step 2. Inspect Electrical Connectors And Wiring g01170964 Illustration 43 Typical view of the P2 pressure sensor pin locations (38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5 Volts) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor Sensor Sensor (39) Ground (GND) Oil Pressure Sensor...
  • Page 130 KENR6933 Troubleshooting Section • B. Use the electronic service tool to check for active Not OK – There is a short circuit between the diagnostic codes. Record all active diagnostic sensor harness connector and the ECM. Leave the codes. sensor disconnected. Proceed to Test Step 8. Test Step 5.
  • Page 131 KENR6933 Troubleshooting Section • Expected Result: Not OK – The open circuit diagnostic code remains active when the jumper is installed. The The short circuit diagnostic code is not present when most probable location for the open circuit is in the a new sensor is connected.

  • Page 132: Engine Speed/Timing Sensor Circuit - Test

    KENR6933 Troubleshooting Section • Not OK – One of the following conditions exists: F. Insert the one end of the engine sensor harness The “Voltage Below Normal” diagnostic code is bypass into P2 connector on the engine harness. not active when the harness is disconnected. The Insert the other end of the engine sensor harness “Voltage Above Normal”...
  • Page 133 KENR6933 Troubleshooting Section • • Use this procedure if another procedure has The engine will continue to run when only one directed you here. sensor signal is present from either the primary sensor or the secondary sensor. • The engine will not start and the electronic service •...
  • Page 134 KENR6933 Troubleshooting Section Table 39 P2/J2 Pin Connections Function Sensor Pin Crankshaft Primary Sensor Camshaft Secondary Sensor +8 Volt Supply Signal g01253286 Illustration 44 Schematic for the speed/timing sensors g01188474 Illustration 45 Pin locations on the P2 connector for the speed/timing sensors (10) Speed/ Timing sensor supply (8 Volts (52) Crankshaft speed timing sensor signal (53) Pump/Cam speed sensor signal (Sig)
  • Page 135 KENR6933 Troubleshooting Section g01188476 Illustration 46 Sensor locations (1) Primary speed/timing sensor (2) Secondary speed/timing sensor...
  • Page 136 KENR6933 Troubleshooting Section g01253714 Illustration 47 Detailed view of the sensor locations (1) Primary speed/timing sensor (2) Secondary speed/timing sensor g01212995 Illustration 48 Typical example of the speed/timing sensor (1) Voltage Supply (8 Volts DC) (2) Signal (Sig) Test Step 1. Inspect the Electrical G.
  • Page 137 KENR6933 Troubleshooting Section Test Step 3. Check the Harness Between If a sensor must be replaced or the sensor must be the Secondary Speed/Timing Sensor and reinstalled, complete all of the following tasks: the ECM • Lubricate the O ring with clean engine lubricating oil.
  • Page 138 KENR6933 Troubleshooting Section Expected Result: Repair: Repair the faulty connectors or replace the faulty connectors. Repair the faulty harness or The readings agree with the values that are listed replace the faulty harness. Reconnect all sensor above. and ECM connectors. Ensure that all of the seals are correctly in place.
  • Page 139 KENR6933 Troubleshooting Section Test Step 7. Check if a Replacement Test Step 8. Check if the Replacement of Sensor Eliminates the Fault the ECM Eliminates the Fault A. Turn the keyswitch to the OFF position. A. Temporarily connect a test ECM. The test ECM must be programmed with the correct software.

  • Page 140: Engine Temperature Sensor Open Or Short Circuit - Test

    KENR6933 Troubleshooting Section The ECM continuously outputs a pull-up voltage on i02657152 the circuit for the sensor signal wire. The ECM uses Engine Temperature Sensor this pull-up voltage in order to detect an open in the Open or Short Circuit - Test signal circuit.
  • Page 141 KENR6933 Troubleshooting Section g01249915 Illustration 49 Schematic for engine temperature sensors • 0172-04 Intake Manifold Air Temperature Sensor voltage below normal Expected Result: One or more of the preceding diagnostic codes are active or recently logged. Results: • Yes – Proceed to Test Step 2. •...
  • Page 142 KENR6933 Troubleshooting Section Test Step 2. Inspect Electrical Connectors And Wiring g01170936 Illustration 51 Typical view of the P2 pin locations on the temperature sensor (37) Ground (GND) Intake Manifold Air (42) Signal (SIG) Intake Manifold Air (43) Signal (SIG) Coolant Temperature Temperature Sensor and Coolant Temperature Sensor Sensor...
  • Page 143 KENR6933 Troubleshooting Section • Results: Not OK – There is a short circuit between the sensor harness connector and the ECM. Leave the • OK - SHORT Circuit – A “Voltage Below Normal” sensor disconnected. Proceed to Test Step 6. diagnostic code is active at this time.
  • Page 144 KENR6933 Troubleshooting Section • Note: The “Voltage Above Normal” diagnostic code Not OK – The “Voltage Above Normal” diagnostic for the temperature sensor that is not suspect should code remains active with the jumper in place. The most probable location for the open circuit is in the become active when the sensor common connection sensor common or the sensor signal wire in the is removed from the P2 connector.

  • Page 145: Fuel Rail Pump Solenoid - Test

    The fuel rail pump is not serviceable part. Test Step 8. Perform the “Wiggle Test” on The fuel rail pump delivers fuel into the fuel rail at the Perkins Electronic Service Tool (EST) very high pressure. A. Select the “Wiggle Test” from the diagnostic tests Use this procedure to troubleshoot the system when on the electronic service tool.
  • Page 146 KENR6933 Troubleshooting Section The fuel rail pump solenoid forms part of the closed loop control system for the fuel rail pressure in conjunction with the fuel rail pressure sensor, ECM and the software. The fuel rail pressure sensor measures the fuel pressure in the high pressure fuel rail.
  • Page 147 ECM. • 1779-06 – Proceed to Test Step 7. E. Perform a “Wiggle Test” by using the Perkins EST • in order to identify intermittent connections. Not OK – No active diagnostic codes or recently logged diagnostic codes are displayed.
  • Page 148 KENR6933 Troubleshooting Section Test Step 4. Check the Fuel Rail Pump Use the electronic service tool in order to clear all Solenoid for an Open Circuit logged diagnostic codes and then verify that the repair eliminates the fault. A. Turn the keyswitch to the OFF position. STOP.
  • Page 149 Turn the keyswitch to the ON position. G. Monitor the status screen on the electronic service tool. Use the Perkins EST in order to perform the fuel rail pump solenoid test. Expected Result: Use the electronic service tool in order to clear all The fault is eliminated.

  • Page 150: Ignition Keyswitch Circuit And Battery Supply Circuit - Test

    KENR6933 Troubleshooting Section Usually, battery power to the diagnostic connector i02659963 is available and the battery power to the data link Ignition Keyswitch Circuit and connector is independent of the keyswitch. Therefore, Battery Supply Circuit - Test you will be able to power up the electronic service tool, but you may not be able to communicate with the engine ECM.
  • Page 151 KENR6933 Troubleshooting Section g01245123 Illustration 54 Schematic for the ignition keyswitch and battery supply circuit g01193796 Illustration 55 Typical rear view of the pin locations for the ignition keyswitch and battery supply circuit (1) Battery ground (GND) (8) Battery (+) (16) Battery ground (+) (2) Battery ground (GND) (9) Battery ground (GND)
  • Page 152 KENR6933 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 153 KENR6933 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 154 KENR6933 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 155: Indicator Lamp Circuit - Test

    KENR6933 Troubleshooting Section D. Remove the fuses from the Battery+ wire of the i02660145 bypass harness and connect the Battery+ and the Indicator Lamp Circuit - Test Battery- wires directly to the battery terminals. Note: This bypass directly connects the circuit for the keyswitch to the ECM.
  • Page 156 KENR6933 Troubleshooting Section g01336446 Illustration 57 Typical schematic of the indicator lamp circuit g01176466 Illustration 58 Typical example of the P1 OEM connector pin locations (1) Ground (7) Battery+ (59) Warning lamp (2) Ground (8) Battery+ (60) Stop lamp (3) Ground (15) Battery+ (61) PTO lamp (9) Ground...
  • Page 157 KENR6933 Troubleshooting Section E. Check the harness for abrasions and for pinch Note: The “Override” function is contained in the points from the battery to the ECM. “Diagnostics” menu of the electronic service tool. Results: C. Measure the voltage at the lamp socket. •...

  • Page 158: Injector Data Incorrect - Test

    KENR6933 Troubleshooting Section Use the electronic service tool in order to clear all 5. If the fault returns with the suspect ECM, then logged diagnostic codes and then verify that the replace the suspect ECM. repair eliminated the fault. STOP. STOP.
  • Page 159 KENR6933 Troubleshooting Section • If the ECM is replaced then the replacement 4-2 Cylinder #4 Injector erratic, intermittent, or ECM must be correctly programmed. Refer to incorrect Troubleshooting, “Replacing the ECM” for further • information. 5-2 Cylinder #5 Injector erratic, intermittent, or incorrect Use the electronic service tool in order to perform the •...

  • Page 160: Injector Solenoid Circuit - Test

    KENR6933 Troubleshooting Section • Not OK – The diagnostic codes indicate the Results: cylinder numbers that have faulty injectors. • OK – The test ECM eliminates the fault and the Repair: Replace the faulty injectors. suspect ECM indicates a “FAIL” condition. Replace the faulty ECM.
  • Page 161 KENR6933 Troubleshooting Section These engines have Electronic Unit Injectors (EUI) that are mechanically actuated and electronically controlled. The Electronic Control Module (ECM) sends a pulse to each injector solenoid. The pulse is sent at the correct time and at the correct duration for a given engine load and speed.
  • Page 162 KENR6933 Troubleshooting Section g01336711 Illustration 61 Schematic for the injector solenoid circuit for the 1106C Genset g01171366 Illustration 62 P2 pin connections for the 1106C Genset (57) Injector Cylinder (Number 1) (59) Injector Cylinder (Number 3) (63) Injector Cylinder (Number 5)
  • Page 163 KENR6933 Troubleshooting Section g01245543 Illustration 63 Typical example of the fuel injector harness connector g01245544 Illustration 64 Typical example of the connector on the valve mechanism cover Test Step 1. Inspect Electrical Connectors Expected Result: and Wiring All connectors, pins, and sockets are completely coupled and/or inserted and the harness is free of corrosion, of abrasion and of pinch points.
  • Page 164 KENR6933 Troubleshooting Section Test Step 2. Check for Logged Diagnostic E. Access the “Injector Solenoid Test” by accessing Codes that are Related to the Injector the following display screens in order: Solenoids • “Diagnostics” A. Connect the electronic service tool to the •...
  • Page 165 KENR6933 Troubleshooting Section • “Cylinder Cutout Test” D. Fabricate a jumper wire 100 mm (4 inch) long with terminals on both ends of the wire. D. Select the start button at the bottom of the screen for the cylinder cutout test on the electronic E.
  • Page 166 KENR6933 Troubleshooting Section G. Turn the keyswitch to the ON position. D. Reinstall connector P2 to the ECM. H. Perform the “Injector Solenoid Test” at least two E. Turn the keyswitch to the ON position. times. F. Perform the “Injector Solenoid Test” at least two Expected Result: times.
  • Page 167 KENR6933 Troubleshooting Section Test Step 8. Check the Harness between Note: When the engine harness is disconnected, the ECM and the Valve Cover Base for a all of the diagnostic codes for supply voltage to the Short Circuit sensors will be active. This is normal. Clear all of the logged diagnostic codes after completing this test step.

  • Page 168: Speed Demand Circuit (Analog) - Test

    KENR6933 Troubleshooting Section D. Turn the keyswitch to the ON position. Results: • E. Perform the “Injector Solenoid Test” at least two OK – The resistance is greater than 10 Ohms. times. Repair: Reconnect connector P2. Expected Result: Replace the faulty injector. All of the injectors that were disconnected indicate “Current Below Normal”.
  • Page 169 Note: In other applications, the analog voltage output is generated by an accelerator or a hand throttle. These terms will still be displayed on the electronic service tool for this application. Use the Perkins EST in order to check the input status. Table 40 P1 Pin Connections...
  • Page 170 C. Temporarily remove the pin from P1:54. A. Turn the keyswitch to the ON position. D. Reconnect P1 OEM connector. B. Use the Perkins EST to check for diagnostic E. Connect the red probe of a multimeter to the codes.

  • Page 171: Speed Demand Circuit (Digital) - Test

    KENR6933 Troubleshooting Section Expected Result: The digital speed demand device is used to provide a digital speed demand signal to the Engine Control The signal at the ECM is the same value as the Module (ECM). The output from the device is a output signal from the control system.
  • Page 172 KENR6933 Troubleshooting Section g01228375 Illustration 67 Typical schematic of the digital speed demand device g01228377 Illustration 68 Typical example of the pin locations on the P1 OEM connector (33) Digital speed demand device return (53) Digital speed demand device input Test Step 1.
  • Page 173 Test Step 2. Check for Active Diagnostic Codes D. Reconnect P1 OEM connector. A. Connect Perkins EST to the data link connector. E. Connect the red probe of a multimeter to the removed pin and the black probe of a multimeter to P1:33.

  • Page 174: Starting Aid (Glow Plug) Relay Circuit - Test

    KENR6933 Troubleshooting Section i02661788 Starting Aid (Glow Plug) Relay Circuit - Test System Operation Description: Use this procedure if another test procedure has directed you here. Use this procedure for the following diagnostic codes: • 2246-06 Glow Plug Start Aid Relay Current above normal The following background information is related to this procedure:...
  • Page 175 KENR6933 Troubleshooting Section g01337191 Illustration 69 Typical schematic for the starting aid switch g01205132 Illustration 70 Typical view of the pin locations on the P1 connector (1) Ground (GND) (9) Ground (GND) (63) Cold start lamp (2) Ground (GND) (10) Ground (GND) (3) Ground (GND) (57) Start aid control...
  • Page 176 KENR6933 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 177 KENR6933 Troubleshooting Section Results: The keyswitch is in the ON position. The measured voltage for the 12 Volt systems is a constant 10.5 to • OK – The harness connects the ECM to the glow 13.5 Volts DC. 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 Volts DC.

  • Page 178: Wastegate Solenoid - Test

    KENR6933 Troubleshooting Section i02662105 Wastegate Solenoid - Test System Operation Description: Use this procedure under the following conditions: Use this procedure if another procedure has directed you here. Use this procedure if any of the following diagnostic codes are active: •...
  • Page 179 KENR6933 Troubleshooting Section g01245700 Illustration 71 Schematic for the wastegate regulator g01245711 Illustration 72 Wastegate regulator connector (1) Ground (GND) (2) Signal (SIG) g01172793 Illustration 73 Typical view of the pin locations on the P1 connector (17) Wastegate pulse width modulation (PWM) signal (44) Wastegate return...
  • Page 180 STOP. C. Turn the keyswitch to the ON position. Start the Test Step 3. Determine the Diagnostic Perkins EST. Code that is Active D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes. A. Turn the keyswitch to the ON position. Access the “Diagnostics Tests”...
  • Page 181 KENR6933 Troubleshooting Section • Not OK – Diagnostic code 526-6 is active at this B. Temporarily remove the wires from P2:17 and time. Proceed to Test Step 6. P2:44. • Not OK – Diagnostic code 526-7 is active at this C.
  • Page 182 KENR6933 Troubleshooting Section C. Turn the keyswitch to the ON position. Access the Use the electronic service tool in order to clear all “Diagnostics Tests” on the electronic service tool. logged diagnostic codes and then verify that the Activate the “Turbo Wastegate Solenoid Test”. repair eliminated the fault.

  • Page 183: Index

    KENR6933 Index Section Index Numerics CID 0110 FMI 03 ........... 86 CID 0110 FMI 04 ........... 86 5 Volt Sensor Supply Circuit - Test ...... 104 CID 0168 FMI 00 ........... 86 CID 0168 FMI 01 ........... 87 CID 0168 FMI 02 ........... 87 CID 0172 FMI 03 ...........
  • Page 184 Recommended Actions........44 Glossary ..............7 Electronic Service Tools ......... 11 Optional Service Tools ........11 Perkins Electronic Service Tool......12 Required Service Tools ........11 Electronic Troubleshooting ........5 Ignition Keyswitch Circuit and Battery Supply Circuit - Engine Cranks but Will Not Start ......45 Test ..............
  • Page 185 KENR6933 Index Section Mechanical Noise (Knock) in Engine..... 68 Wastegate Solenoid - Test........178 Probable Causes ..........68 Recommended Actions........68 No Diagnostic Codes Detected ......72 Noise Coming from Cylinder........68 Probable Causes ..........68 Recommended Actions........68 Programming Parameters ........26 Replacing the ECM..........
  • Page 186 KENR6933 Index Section...
  • Page 187 KENR6933 Index Section...
  • Page 188 Copyright ©2007 Perkins Engines Company Limited All Rights Reserved Printed in U.K.

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