Perkins NJ Series Troubleshooting Manual
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Perkins NJ Series Troubleshooting Manual

Industrial engines
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SENR9982-01
May 2006
Troubleshooting
1104D and 1106D Industrial Engines
NH (Engine)
NJ (Engine)
PJ (Engine)

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Summary of Contents for Perkins NJ Series

  • Page 1 SENR9982-01 May 2006 Troubleshooting 1104D and 1106D Industrial Engines NH (Engine) NJ (Engine) PJ (Engine)
  • Page 2 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

    SENR9982-01 Table of Contents Table of Contents Intermittent Engine Shutdown ....... 71 Intermittent Low Power or Power Cutout ....72 Low Engine Oil Pressure ........73 Low Power/Poor or No Response to Throttle ..74 Troubleshooting Section Mechanical Noise (Knock) in Engine ....76 Noise Coming from Cylinder .........
  • Page 4 SENR9982-01 Table of Contents CID 0774 FMI 03 ..........103 CID 0774 FMI 04 ..........104 CID 0774 FMI 08 ..........105 CID 1639 FMI 09 ..........105 CID 1743 FMI 02 ..........105 CID 1779 FMI 05 ..........106 CID 1779 FMI 06 ..........

  • Page 5: Troubleshooting Section

    SENR9982-01 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i02488451 System Overview System Operation g01236714 Illustration 1 1104D engine (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...
  • Page 6 SENR9982-01 Troubleshooting Section g01178531 Illustration 2 1106D engine (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) (4) Secondary Speed/Timing Sensor...
  • Page 7 SENR9982-01 Troubleshooting Section The engine is designed for electronic control. The • Speed/timing sensors engine has an Electronic Control Module (ECM), a fuel rail pump and electronic unit injectors. All of • Throttle position sensor these items are electronically controlled. There are also a number of engine sensors.

  • Page 8: Glossary

    Factory passwords are calculated on a computer system that is available only to Coolant Temperature Sensor – The coolant Perkins distributors. Since factory passwords contain temperature sensor detects the engine coolant alphabetic characters, only an electronic service temperature for all normal operating conditions and tool may change System Configuration Parameters.
  • Page 9 1 – The data is valid but the data is below the normal DT, DT Connector, or Deutsch DT – This is a type operational range. of connector that is used on Perkins engines. The connectors are manufactured by Deutsch. 2 – The data is erratic, intermittent, or incorrect.
  • Page 10 SENR9982-01 Troubleshooting Section Flash File – This file is software that is inside Full Torque Setting (FTS) – The FTS is the the ECM. The file contains all the instructions parameter that represents the adjustment for the (software) for the ECM and the file contains the engine torque.
  • Page 11 SENR9982-01 Troubleshooting Section Intake Manifold Pressure Sensor – The Intake Pulse Width Modulation (PWM) – The PWM is a Manifold Pressure Sensor measures the pressure signal that consists of pulses that are of variable in the intake manifold. The pressure in the intake width.

  • Page 12: Electronic Service Tools

    Tattletale – Certain parameters that affect the operation of the engine are stored in the ECM. These parameters can be changed by use of the Perkins electronic service tools are designed to help electronic service tool. The tattletale logs the number the service technician: of changes that have been made to the parameter.
  • Page 13 Perkins Electronic Service Tool Electronic Service Tool and the PC requirements for the Electronic Service Tool, refer to the documentation that accompanies your Perkins The Perkins Electronic Service Tool can display the Electronic Service Tool software. following information: • Status of all pressure sensors and temperature...

  • Page 14: Indicator Lamps

    SENR9982-01 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 15 SENR9982-01 Troubleshooting Section Operation of the Indicator Lamps Table 4 Warning Shutdown Lamp State Description of the Indication Engine State Lamp Lamp (Alert (Action Lamp) Lamp) Lamp Check When the keyswitch is switched on, the lamps The keyswitch is on but the come on for a period of 2 seconds and the lamps engine has not yet been will then go off.
  • Page 16 SENR9982-01 Troubleshooting Section The sequence for the flash code is started by moving the keyswitch to “Off” and then moving the keyswitch to “On” twice within a period of three seconds. After a delay of 2 seconds, the “Shutdown” lamp will flash once for a period of half a second.

  • Page 17: Replacing The Ecm

    SENR9982-01 Troubleshooting Section i02517235 NOTICE Replacing the ECM If the flash file and engine application are not matched, engine damage may result. Perform the following procedure in order to replace NOTICE the ECM. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- 1.

  • Page 18: Self-Diagnostics

    SENR9982-01 Troubleshooting Section 8. If necessary, use the electronic service tool to Logged Code – Every generated code is stored clear the rating interlock. To clear the rating in the permanent memory of the ECM. The codes interlock, enter the factory password when the are logged for 100 operating hours unless a code is electronic service tool is first connected.
  • Page 19 SENR9982-01 Troubleshooting Section g01248060 Illustration 6 Sensor locations on the 1104D engine (1) Fuel Rail Pressure Sensor (5) Oil Pressure Sensor (9) Intake Manifold Pressure Sensor (2) Intake Manifold Air Temperature Sensor (6) Oil Pressure Sensor (alternative location) (10) Intake Manifold Pressure Sensor (3) Electronic Control Module (ECM) (7) Secondary Speed/Timing Sensor (alternative location)
  • Page 20 SENR9982-01 Troubleshooting Section g01248066 Illustration 7 Close up views of the sensor locations on the 1104D engine...
  • Page 21 SENR9982-01 Troubleshooting Section g01178874 Illustration 8 Sensor locations on the 1106D engine (1) Coolant Temperature Sensor (4) Fuel Rail Pressure Sensor (7) Primary Speed/Timing Sensor (2) Intake Manifold Air 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...
  • Page 22 SENR9982-01 Troubleshooting Section g01178875 Illustration 9 Close up views of the sensor locations on the 1106D engine...
  • Page 23 SENR9982-01 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 24 SENR9982-01 Troubleshooting Section g01236714 Illustration 10 Schematic diagram for the 1104D engine (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 25: Engine Wiring Information

    Engine Wiring Information Harness Wire Identification Perkins identifies all wires with eleven solid colors. The circuit number is stamped on the wire at a 25 mm (1 inch) spacing. Table 6 lists the wire colors and the color codes.
  • Page 26 SENR9982-01 Troubleshooting Section Table 6 Color Codes for the Harness Wire Color Code Color Color Code Color Black Blue Brown Purple Gray Orange White Yellow Pink Green For example, a wire identification of F730-OR on the schematic would signify an orange wire with the circuit number F730.
  • Page 27 SENR9982-01 Troubleshooting Section Schematic Diagrams g01238742 Illustration 12 Schematic Diagram for the 1104D Engine Harness...
  • Page 28 SENR9982-01 Troubleshooting Section g01258486 Illustration 13 Schematic Diagram for the 1106D Engine Harness...

  • Page 29: Ecm Harness Connector Terminals

    SENR9982-01 Troubleshooting Section g01246520 Illustration 14 Schematic Diagram for a Typical Application Note: The functionality of most of the connections to the J1 connector depend on the engine application. i02414687 ECM Harness Connector Terminals The Electronic Control Module (ECM) uses connectors that have 64 terminals to interface to the wiring harness.
  • Page 30 SENR9982-01 Troubleshooting Section Removal and Installation of the Harness Connector Terminals Terminal Removal Table 7 Required Tools Part Number Part Description 27610285 Removal Tool g01201632 Illustration 17 Removal Tool 3. Insert the removal tool into the hole that is adjacent to the terminal in order to release the locking device.

  • Page 31: Programming Parameters

    SENR9982-01 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 32: Factory Passwords

    Be sure the flash g00627693 Illustration 18 file is correct for your engine. Typical “Raise/Resume” Switch for the PTO (1) OFF position Note: Factory passwords are provided only to (2) RAISE position Perkins dealers. (3) RESUME position...

  • Page 33: Factory Passwords Worksheet

    PC to the ECM. Flash Programming a Flash File 1. Obtain the part number for the new flash file. Note: If you do not have the part number for the flash file, use “PTMI” on the Perkins Internet.

  • Page 34: Injector Trim File

    1 or more. If a parameter has a tattletale of 0, program that parameter. • Select “Service Software Files” on the Perkins Internet. “WinFlash” Error Messages • Use the compact disc that is included with a If you receive any error messages during flash replacement electronic unit injector.

  • Page 35: Mode Switch Setup

    SENR9982-01 Troubleshooting Section Mode Selection Number 5. Connect the electronic service tool to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”. This parameter is a non-programmable parameter that represents the number of possible combinations 6. Turn the keyswitch to the ON position. of switch positions.

  • Page 36: Throttle Setup

    SENR9982-01 Troubleshooting Section Table 12 Table 16 Range Default Factory Password Throttle 1 Throttle 2 PWM (Digital Throttle) Analog Throttle “Programmed 5.0% Low Idle” to PWM (Digital Throttle) None “Programmed High Idle” PWM (Digital Throttle) Multi-position Throttle Switch Throttle 1 Droop Percentage Analog Throttle Analog Throttle Analog Throttle...
  • Page 37 SENR9982-01 Troubleshooting Section If the ECM detects a throttle percentage below this value with the idle validation switch OFF (Open), a fault code will be generated and the engine will remain at idle. Refer to Table 18 and Table 19. g01264476 Illustration 19 Typical Range of Throttle...
  • Page 38 SENR9982-01 Troubleshooting Section Table 18 Throttle Position Idle Validation Switch Throttle Demand Fault Status Comment Sensor (TPS) (IVS) Output TPS< IVS Min OFF Minimum Position Raise missing idle Force throttle demand to minimum TPS< IVS Min OFF Throttle Position Clear missing idle Normal operation Table 19 Range...

  • Page 39: Multiposition Switch Setup

    SENR9982-01 Troubleshooting Section Table 24 Table 29 Range Default Range Default 0 to 100% 0 to 100% Upper Position Limit i02415246 Multiposition Switch Setup This is the maximum throttle percentage that will be interpreted by the ECM as full throttle. This parameter is used with the value of the initial upper position limit to make an allowance for manufacturing tolerances The multi-position throttle switch is an optional...
  • Page 40 SENR9982-01 Troubleshooting Section Table 31 Value Default Logical Position The Logical Position is the order that is required by the user for a unique Physical Position. Table 32 Range Default 1 to 16 Engine Speed (in RPM) The “Engine Speed” is the programmed engine rpm for a particular position of the multi-position throttle switch.

  • Page 41: Customer Specified Parameters

    SENR9982-01 Troubleshooting Section Customer Specified Table 36 Minimum Maximum Default Parameters 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 42 SENR9982-01 Troubleshooting Section Table 39 Table 43 Minimum Maximum Default Value Default 0 rpm 3000 rpm 0 rpm Disabled Enabled Enabled Throttle Lock Increment Speed Ramp Limp Home Desired Engine Speed Rate The “Limp Home Desired Engine Speed” is the The “Throttle Lock Increment Speed Ramp Rate”...
  • Page 43 SENR9982-01 Troubleshooting Section Table 46 Value Default Installed Not Installed Not Installed 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 44: Customer Specified Parameters Table

    SENR9982-01 Troubleshooting Section i02527577 Customer Specified Parameters Table Table 50 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 45: Customer Specified Parameters Worksheet

    SENR9982-01 Troubleshooting Section i02415254 Customer Specified Parameters Worksheet Table 51 Customer Specified Parameters Worksheet Engine Rating Parameter “Rating Numbers” Low/High Idle Parameters “Low Idle Speed” “High Idle Speed” ECM Identifications Parameters “Equipment ID” PTO and Throttle Lock Parameters “Throttle Lock Feature Installation Status” “PTO Engine Speed Setting”...

  • Page 46: System Configuration Parameters

    SENR9982-01 Troubleshooting Section System Configuration Note: The flash programming of a new rating interlock replaces the old rating interlock. Parameters This code does not need to be programmed when the replacement ECM is for the same engine rating. i02527574 If the ECM is for a different engine rating, then the System Configuration following components may need to be changed: Parameters...

  • Page 47: Troubleshooting Without A Diagnostic Code

    SENR9982-01 Troubleshooting Section Troubleshooting without a Alternator Bearings Diagnostic Code Check for excessive play of the shaft in the alternator. Check for wear in the alternator bearings. The alternator is a nonserviceable item. The alternator must be replaced if the bearings are worn. Refer to i02528126 Disassembly and Assembly, “Alternator - Remove”...

  • Page 48: Battery

    SENR9982-01 Troubleshooting Section • Throttle signal from the throttle position sensor i02344743 Battery • Air intake and exhaust system • Fuel supply Note: This is not an electronic system problem. • Individual malfunctioning cylinders Probable Causes • Electronic unit injectors •...
  • Page 49 SENR9982-01 Troubleshooting Section 3. If the engine has a throttle switch refer to 9. Ensure that the fuel system has been primed. Troubleshooting, “Throttle Switch Circuit - Test”. Refer to Testing and Adjusting, “Fuel System - Prime”. 4. If the fault has not been eliminated, proceed to “Air Intake and Exhaust System”.

  • Page 50: Coolant In Engine Oil

    SENR9982-01 Troubleshooting Section Electronic Unit Injectors Cylinder Head Gasket 1. With the engine speed at a fast idle, use the 1. Remove the cylinder head. Refer to Disassembly electronic service tool to isolate one cylinder at and Assembly, “Cylinder Head - Remove” for the a time.

  • Page 51: Coolant Temperature Is Too High

    SENR9982-01 Troubleshooting Section Coolant Temperature Gauge i02528229 Coolant Temperature Is Too Compare the reading for the coolant temperature High from the electronic service tool to the reading for the coolant temperature from a calibrated test gauge. Restriction in the Coolant System Note: This is not an electronic system problem.

  • Page 52: Ecm Will Not Accept Factory Passwords

    Wiring to display modules • Serial numbers • Wiring to other control modules • Total tattletale 3. Troubleshoot the Perkins Data Link for possible problems. Refer to Troubleshooting, “Data Link • Reason code Circuit - Test”. Recommended Actions i02535551 Electronic Service Tool Will 1.

  • Page 53: Engine Cranks But Will Not Start

    Electrical Connectors Perkins Data Link Check for correct installation of the P1/J1 and P2/J2 Troubleshoot the Perkins Data Link for possible ECM connectors and of the service tool connector. faults. Refer to Troubleshooting, “Data Link Circuit - Refer to Troubleshooting, “Electrical Connectors - Test”.
  • Page 54 SENR9982-01 Troubleshooting Section • Electronic control system • Improper timing of valves • High pressure fuel system 3. If the crankshaft rotates freely proceed to “Air Intake and Exhaust System”. Recommended Actions Air Intake and Exhaust System NOTICE 1. Check the air filter restriction indicator, if equipped. Do not crank the engine continuously for more than 30 seconds.
  • Page 55 SENR9982-01 Troubleshooting Section Electronic Control System 2. Ensure that the fuel supply valve (if equipped) is in the full OPEN position. 1. Use the electronic service tool to check that fuel 3. If the temperature is below 0 °C (32 °F), check pressure is present in the fuel rail when the engine for solidified fuel (wax).

  • Page 56: Engine Has Early Wear

    SENR9982-01 Troubleshooting Section Dirt in Engine Oil 2. Crank the engine and measure the leakage from the return line for the electronic unit injectors. If the leakage at an minimum engine cranking speed of 1. Drain the oil from the crankcase and refill the 150 RPM is greater than 0.1 L/min (0.2 Pints/min), crankcase with clean engine oil.
  • Page 57 SENR9982-01 Troubleshooting Section Note: If the fault is intermittent and the problem 3. Check the air intake and exhaust systems for the cannot be duplicated, refer to Troubleshooting, following defects: “Intermittent Low Power or Power Cutout”. • Blockages Note: If the fault only occurs under certain conditions, test the engine under those conditions.

  • Page 58: Engine Oil In Cooling System

    SENR9982-01 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 59: Engine Speed Does Not Change

    SENR9982-01 Troubleshooting Section 2. Check for leaks in the oil cooler assembly. Refer i02534845 to Testing and Adjusting, “Cooling System” for the Engine Speed Does Not correct procedure. If a leak is found, install a new Change oil cooler. Refer to Disassembly and Assembly, “Engine Oil Cooler - Remove”...

  • Page 60: Engine Stalls At Low Rpm

    SENR9982-01 Troubleshooting Section 4. Check the primary filter/water separator for water i02534896 in the fuel. Engine Stalls at Low RPM 5. Check for fuel supply lines that are restricted. 6. Check that the low pressure fuel lines are tight Probable Causes and secured properly.

  • Page 61: Engine Vibration

    SENR9982-01 Troubleshooting Section 2. If low compression is noted on any cylinders, i02414532 investigate the cause and rectify the cause. Engine Vibration Possible causes of low compression are shown in the following list: Note: This is not an electronic system fault. •...

  • Page 62: Engine Will Not Crank

    SENR9982-01 Troubleshooting Section 2. Remove the electronic unit injector from the 6. If there are no active diagnostic codes refer to suspect cylinder. Refer to Disassembly and the Troubleshooting Manual for your machine Assembly, “Electronic Unit Injector - Remove”. application. 3.

  • Page 63: Excessive Black Smoke

    SENR9982-01 Troubleshooting Section 4. If the engine does not rotate in Step 2, disassemble 3. If diagnostic codes are present, the Electronic the engine. Refer to Disassembly and Assembly. Control Module (ECM) must be programmed with the correct information. 5. Inspect the internal components for the following conditions: 4.
  • Page 64 SENR9982-01 Troubleshooting Section Individual Malfunctioning Cylinder 6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Testing and Adjusting, “Wastegate - Inspect”. If the wastegate actuator 1. With the engine speed at a fast idle, use the is faulty, replace the wastegate actuator.

  • Page 65: Excessive Engine Oil Consumption

    SENR9982-01 Troubleshooting Section Oil Level i02528860 Excessive Engine Oil 1. Check the oil level in the engine. Consumption 2. If the oil level is high, check for contamination of the oil with coolant. Refer to Troubleshooting, “Coolant in Engine Oil”. Probable Causes 3.

  • Page 66: Excessive Fuel Consumption

    SENR9982-01 Troubleshooting Section Low Compression (cylinder pressure) • Failure of the primary speed/timing sensor 1. Perform a compression test. Refer to Testing and Recommended Actions Adjusting, “Compression - Test ”. Diagnostic Codes 2. If low compression is noted on any cylinders, investigate the cause and rectify the cause.
  • Page 67 SENR9982-01 Troubleshooting Section 4. If the oil is of an acceptable quality, refer to 1. Check the air intake system for leakage or “Operation in Cold Conditions”. restrictions. Refer to Testing and Adjusting, “Air Inlet and Exhaust System”. Low Engine Temperature 2.

  • Page 68: Excessive Valve Lash

    SENR9982-01 Troubleshooting Section 1. Use the electronic service tool to check for 2. Check the components for the following active diagnostic codes that relate to the primary conditions: abnormal wear, excessive wear, speed/timing sensor. straightness, and cleanliness. If necessary, use new parts for replacement.

  • Page 69: Intake Air Temperature Is Too High

    SENR9982-01 Troubleshooting Section Low Coolant Temperature 3. Perform all necessary repairs. Check that the water temperature regulator is 4. Ensure that the repairs have eliminated the faults. operating correctly. Refer to Testing and Adjusting, “Water Temperature Regulator - Test”. 5. If the repair does not eliminate the fault refer to “Individual Malfunctioning Cylinder”.
  • Page 70 Measure the intake manifold pressure while the engine is operating under load. For specific data, 2. Inspect the air charge cooler for contamination refer to the Perkins Technical Marketing Information and/or bent fins or damaged fins. for the engine. 3. If necessary, clean the air charge cooler.

  • Page 71: Intermittent Engine Shutdown

    SENR9982-01 Troubleshooting Section 4. Inspect the battery wires from the ECM to the i02518234 battery compartment. Refer to the Schematic Intermittent Engine Shutdown Diagram. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refer to the schematic diagram for more information.

  • Page 72: Intermittent Low Power Or Power Cutout

    SENR9982-01 Troubleshooting Section 3. If a fault is suspected with the ECM power and i02535522 ground connections refer to Troubleshooting, Intermittent Low Power or “Electrical Power Supply Circuit - Test”. Power Cutout 4. Verify that the ECM connections for the power and ground connections at the fuel pump are correctly connected.

  • Page 73: Low Engine Oil Pressure

    SENR9982-01 Troubleshooting Section Oil Specification 3. The intake manifold pressure should read 0 ± 0.5 kPa (0 ± 0.07 psi). If the intake manifold pressure is not within the limits, perform the 1. Make sure that engine oil of the correct following steps.

  • Page 74: Low Power/Poor Or No Response To Throttle

    SENR9982-01 Troubleshooting Section Engine Oil Suction Tube • Turbocharger 1. Check the inlet screen on the oil suction tube • Fuel supply and remove any material that may be restricting • oil flow. Low compression (cylinder pressure) 2. Check the joints of the oil suction tube for cracks •...
  • Page 75 SENR9982-01 Troubleshooting Section 4. Run the engine until the speed is equal to the 2. Check that the oil drain for the turbocharger is not maximum no-load speed. blocked or restricted. 5. Use the electronic service tool to make sure that 3.

  • Page 76: Mechanical Noise (Knock) In Engine

    SENR9982-01 Troubleshooting Section Electronic Unit Injectors 12. If the repair does not eliminate the fault refer to “Low Compression (Cylinder Pressure)”. 1. Use the electronic service tool to perform the “Cylinder Cut-out Test”. Note if there is any Low Compression (Cylinder Pressure) reduction in engine speed.

  • Page 77: Noise Coming From Cylinder

    SENR9982-01 Troubleshooting Section Valve Train Components c. Fill the fuel system with fuel that meets the standard in Operation and Maintenance 1. Remove the valve mechanism cover. Check the Manual, “Fluid Recommendations”. following items for damage: camshaft, valve springs, lifters, pushrods, and bridges. Thoroughly d.

  • Page 78: Troubleshooting With A Diagnostic Code

    SENR9982-01 Troubleshooting Section Troubleshooting with a Diagnostic Code i02489089 Diagnostic Code Cross Reference Table 52 3rd Party Device Flash CDL Code Description J1939 Code Code No Diagnostic Code Detected 0001-02 Cylinder #1 Injector erratic, intermittent, or incorrect 651-2 0001-05 Cylinder #1 Injector current below normal 651-5 0001-06 Cylinder #1 Injector current above normal...
  • Page 79 SENR9982-01 Troubleshooting Section (Table 52, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 0091-03 Throttle Position Sensor voltage above normal 91-03 0091-04 Throttle Position Sensor voltage below normal 91-04 0091-08 Throttle Position Sensor abnormal frequency, pulse width, or period 91-08 0100-03 Engine Oil Pressure Sensor voltage above normal...

  • Page 80: No Diagnostic Codes Detected

    SENR9982-01 Troubleshooting Section (Table 52, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 1797-04 Fuel Rail Pressure Sensor voltage below normal 157-04 1834-02 Ignition Key Switch loss of signal 158-02 2246-06 Glow Plug Start Aid Relay current above normal 676-06 Event Codes E172-1...

  • Page 81: Cid 0001 Fmi 05

    SENR9982-01 Troubleshooting Section System Response: An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring If equipped, the warning light will come on. An active that is unique to the electronic unit injector will diagnostic code will be generated.

  • Page 82: Cid 0001 Fmi 07

    SENR9982-01 Troubleshooting Section An electrical fault can prevent the electronic unit Use the electronic service tool to perform the fuel injector from operating. A short circuit in the wiring or system verification test. the ECM that is unique to one electronic unit injector will prevent that individual electronic unit injector from Perform the following diagnostic procedure: “None”...

  • Page 83: Cid 0002 Fmi 05

    SENR9982-01 Troubleshooting Section i02493335 i02498244 CID 0002 FMI 05 CID 0002 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 84: Cid 0002 Fmi 07

    SENR9982-01 Troubleshooting Section • Diagnostic codes 0001-05 and 0001-06 are not i02518295 active. CID 0002 FMI 07 • No 0041 diagnostic codes are active. • No 0262 diagnostic codes are active. Conditions Which Generate This Code: • Diagnostic code 0190-08 is not active. The electronic unit injector is no longer capable of delivering the correct amount of fuel.

  • Page 85: Cid 0003 Fmi 06

    SENR9982-01 Troubleshooting Section Troubleshooting: Troubleshooting: When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors.

  • Page 86: Cid 0004 Fmi 02

    SENR9982-01 Troubleshooting Section Replace the suspect electronic unit injector. Refer i02493337 to Disassembly and Assembly, “Electronic Unit CID 0004 FMI 05 Injector - Remove” and Disassembly and Assembly, “Electronic Unit Injector - Install”. Use the electronic service tool to perform the fuel Conditions Which Generate This Code: system verification test.

  • Page 87: Cid 0004 Fmi 06

    SENR9982-01 Troubleshooting Section i02498249 i02518297 CID 0004 FMI 06 CID 0004 FMI 07 Conditions Which Generate This Code: Conditions Which Generate This Code: This diagnostic code is designed to indicate a short The electronic unit injector is no longer capable of circuit (high current) in either the solenoid or the delivering the correct amount of fuel.

  • Page 88: Cid 0005 Fmi 05

    SENR9982-01 Troubleshooting Section • Diagnostic codes 0001-05 and 0001-06 are not Possible Performance Effect: active. The engine will have low power and/or rough running. • No 0041 diagnostic codes are active. Troubleshooting: • No 0262 diagnostic codes are active. When an injector cutout test is performed, a faulty •...

  • Page 89: Cid 0005 Fmi 07

    SENR9982-01 Troubleshooting Section System Response: Possible Performance Effect: If equipped, the warning light will come on. The ECM The engine will be derated. will log the diagnostic code. Troubleshooting: Possible Performance Effect: Use the electronic service tool to perform the Fuel The engine will have low power and/or rough running.

  • Page 90: Cid 0006 Fmi 05

    SENR9982-01 Troubleshooting Section Possible Performance Effect: An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring The engine will be derated while this diagnostic code that is unique to the electronic unit injector will is active.

  • Page 91: Cid 0006 Fmi 07

    SENR9982-01 Troubleshooting Section Troubleshooting: Replace the suspect electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit When an injector cutout test is performed, a faulty Injector - Remove” and Disassembly and Assembly, electronic unit injector will indicate a low reading in “Electronic Unit Injector - Install”.

  • Page 92: Cid 0041 Fmi 04

    SENR9982-01 Troubleshooting Section System Response: i02526590 CID 0041 FMI 04 The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. Possible Performance Effect: Conditions Which Generate This Code: The engine speed defaults to low idle or a The Electronic Control Module (ECM) detects the predetermined safe speed.

  • Page 93: Cid 0091 Fmi 03

    SENR9982-01 Troubleshooting Section Results: Results: • OK – STOP. • OK – STOP. Test Step 2. i02493481 CID 0091 FMI 03 Perform the following diagnostic procedure: “Digital Throttle Position Sensor Circuit - Test” Results: Conditions Which Generate This Code: • OK –...

  • Page 94: Cid 0091 Fmi 08

    SENR9982-01 Troubleshooting Section If the engine is equipped with a digital throttle position Possible Performance Effect: sensor, proceed to “Test Step 2”. The engine will remain at low idle while the diagnostic code is active. Test Step 1. Throttle inputs are ignored by the ECM until the fault Perform the following diagnostic procedure: “Analog is repaired.

  • Page 95: Cid 0100 Fmi 04

    SENR9982-01 Troubleshooting Section Possible Performance Effect: i02526595 CID 0100 FMI 10 None Troubleshooting: Conditions Which Generate This Code: This diagnostic code can be caused by an open circuit or a short to another power source. The Electronic Control Module (ECM) detects the following conditions: Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”...

  • Page 96: Cid 0110 Fmi 03

    SENR9982-01 Troubleshooting Section • The ECM has been powered for at least two i02526596 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 97: Cid 0168 Fmi 01

    SENR9982-01 Troubleshooting Section • The engine is running for more than 30 seconds. Troubleshooting: System Response: Perform the following diagnostic procedure: “Ignition Keyswitch Circuit and Battery Supply Circuit - Test” The ECM will log the diagnostic code. If equipped, the warning lamp may come on. Results: Possible Performance Effect: •...

  • Page 98: Cid 0172 Fmi 03

    SENR9982-01 Troubleshooting Section i02526601 i02526602 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 99: Cid 0190 Fmi 08

    SENR9982-01 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 100: Cid 0253 Fmi 02

    SENR9982-01 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 101: Cid 0262 Fmi 04

    SENR9982-01 Troubleshooting Section System Response: i02527040 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 102: Cid 0526 Fmi 05

    SENR9982-01 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 103: Cid 0774 Fmi 02

    SENR9982-01 Troubleshooting Section • No 1785 diagnostic codes are active. The engine will remain at this speed while the diagnostic code remains active. • Diagnostic codes 0526-05 and 0526-06 are not active. The reduction of speed is determined by the current speed of the engine.

  • Page 104: Cid 0774 Fmi 04

    SENR9982-01 Troubleshooting Section Possible Performance Effect: • The setting for the lower diagnostic limit has been exceeded for 1 second. Throttle inputs are ignored by the ECM until the fault is repaired. System Response: Throttle inputs will also be ignored by the ECM until The ECM will log the diagnostic code.

  • Page 105: Cid 0774 Fmi 08

    SENR9982-01 Troubleshooting Section Test Step 1. i02527051 CID 0774 FMI 08 Perform the following diagnostic procedure: “Analog Throttle Position Sensor Circuit - Test” Results: Conditions Which Generate This Code: • OK – STOP. The Electronic Control Module (ECM) detects one of the following conditions: Test Step 2.

  • Page 106: Cid 1779 Fmi 05

    SENR9982-01 Troubleshooting Section System Response: i02527058 CID 1779 FMI 06 The ECM will return the engine to the last good mode selection or setting. Possible Performance Effect: Conditions Which Generate This Code: The engine will start and the engine will default to the This diagnostic code indicates that the Electronic previous mode selection.

  • Page 107: Cid 1785 Fmi 04

    SENR9982-01 Troubleshooting Section System Response: For engines with an electronically controlled wastegate, the current for the wastegate solenoid If equipped, the warning light will be on. The ECM will be set to a default value while this code is active. will log the diagnostic code.

  • Page 108: Cid 1797 Fmi 03

    SENR9982-01 Troubleshooting Section Possible Performance Effect: i02527063 CID 1797 FMI 04 • The engine will be derated. Troubleshooting: Conditions Which Generate This Code: This diagnostic code is designed to detect the loss of the 5 V supply to the sensor. The Electronic Control Module (ECM) detects the following conditions: Perform the following diagnostic procedure: “Engine...

  • Page 109: Cid 2246 Fmi 06

    SENR9982-01 Troubleshooting Section Note: This code can be generated by rapidly Troubleshooting: cycling the keyswitch. Some control modules on the application may require this action in order to Perform the following diagnostic procedure: “Starting prompt flash codes. If this occurs, clear the logged Aid (Glow Plug) Relay Circuit - Test”...

  • Page 110: Troubleshooting With An Event Code

    SENR9982-01 Troubleshooting Section Troubleshooting with an Troubleshooting: Event Code The event code may represent a problem with the electronic system. This event code normally indicates high air filter restriction. Refer to Testing i02411237 and Adjusting Manual, “Air Inlet and Exhaust System - Inspect”.

  • Page 111: E232 High Fuel/Water Separator Water Level

    SENR9982-01 Troubleshooting Section Results: System Response: • OK – The event occurred because of normal The event code will be logged. engine operation. Clear the logged event and return the engine to service. STOP. The optional warning lamp will be illuminated. •...
  • Page 112 SENR9982-01 Troubleshooting Section 360-3 • 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 3” area in Illustration 22 for four seconds.

  • Page 113: E361 High Engine Coolant Temperature

    SENR9982-01 Troubleshooting Section 360-3 • Diagnostic code 0168-01 Electrical System voltage low is not active. The warning lamp will flash. 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.

  • Page 114: E362 Engine Overspeed

    The derate of the engine will only occur if the “Enable The event may be viewed by using a display module Derate” customer programmable parameter has or by using the Perkins Electronic Service Tool (EST). been enabled. The ECM will reset the event when the engine speed E361-3 is lower than 2800 RPM for 0.6 seconds.

  • Page 115: E396 High Fuel Rail Pressure

    SENR9982-01 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 116: E539 High Intake Manifold Air Temperature

    SENR9982-01 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 117: E2143 Low Engine Coolant Level

    SENR9982-01 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 118: Diagnostic Functional Tests

    SENR9982-01 Troubleshooting Section Diagnostic Functional • A suspect sensor Tests • A suspect ECM i02490153 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 119 SENR9982-01 Troubleshooting Section Table 55 P2 Pin Connections Function Fuel Rail Pressure Sensor Pin Intake Manifold Oil Pressure Sensor Sensor Pressure Sensor Volts (5 V) Ground Signal Table 56 P1 OEM Connector Sensor Pin Function Analog Throttle Sensor 1 Analog Throttle Sensor 2 5 Volt Sensor Supply Ground...
  • Page 120 SENR9982-01 Troubleshooting Section g01173224 Illustration 24 Typical example of the fuel rail pressure sensor (1) Voltage supply (Vs) (2) Ground (GND) (3) Signal (SIG) g01173225 Illustration 25 Typical example of the intake manifold pressure sensor (1) Voltage Supply (Vs) (2) Ground (GND) (3) Signal (SIG) g01173226 Illustration 26...
  • Page 121 SENR9982-01 Troubleshooting Section g01173227 Illustration 27 Typical example of the P2 pressure sensor pin locations (38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5V)) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor Sensor Sensor (39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (5V) Fuel Rail Pressure (40) Ground (GND) Fuel Rail Pressure Sensor...
  • Page 122 Throttle pedal B. Turn the keyswitch to the ON position. The wire connectors are shown in table 55 and C. Use the Perkins EST in order to monitor the table 56. diagnostic codes. Check and record any active diagnostic codes.
  • Page 123 0262-03 5 Volt Sensor DC Power Supply voltage sensor. Do not install the replacement sensor to above normal the engine. • 0262-04 5 Volt Sensor DC Power Supply voltage B. Use the Perkins EST in order to monitor the below normal diagnostic codes. Results: Expected Result: •...
  • Page 124 SENR9982-01 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 125: Analog Throttle Position Sensor Circuit - Test

    A second sensor may override this speed requirement from the first sensor. This override will be subject to an input from either the SAE J1939 (CAN), or from the PTO controls. Use the Perkins Electronic Service Tool (EST) in order to check the input status.
  • Page 126 SENR9982-01 Troubleshooting Section g01246557 Illustration 30 Schematic of the analog throttle demand sensors g01206986 Illustration 31 Typical view of the P1 connector pin locations (33) Sensor Ground (GND) (41) Sensor supply (5v) (54) Analog throttle input 1 (34) Sensor Ground (GND) (42) Sensor supply (5v) (55) Analog throttle input 2 Test Step 1.
  • Page 127 Status with the Perkins Electronic A. Turn the keyswitch to the ON position. Service Tool (EST). B. Use the Perkins EST to check for diagnostic A. Check the status of the throttle selection switch (if codes. equipped). Use the Perkins EST in order to check Expected Result: the status of the throttle selection switch.
  • Page 128 SENR9982-01 Troubleshooting Section Repair: Check the connections between the Results: throttle selection switch and P1:47 and P1:35. Refer to Troubleshooting, “Electrical Connectors • OK – The throttle demand sensor is operating - Inspect”. correctly. Proceed to Test Step 7. STOP. •...
  • Page 129 SENR9982-01 Troubleshooting Section Note: The test ECM should be programmed with the correct software. All parameters should be set to the same value as the suspected ECM. 2. If the fault is eliminated with the test ECM, install the suspect ECM and verify that the fault returns.

  • Page 130: Can Data Link Circuit - Test

    SENR9982-01 Troubleshooting Section Repair: Replace the sensor. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair has eliminated the fault. STOP. i02490176 CAN Data Link Circuit - Test System Operation Description: Use this procedure under the following circumstances: Use this procedure if another procedure has directed...
  • Page 131 SENR9982-01 Troubleshooting Section g01244083 Illustration 34 Typical example of the schematic for the CAN data link g01209013 Illustration 35 Typical view of the P1 connector pin locations (20) CAN- (21) CAN+ (22) CAN Shield Test Step 1. Inspect Electrical Connectors C.
  • Page 132 SENR9982-01 Troubleshooting Section Results: Repair: Locate the two terminating resistors and remove the two terminating resistors from the • OK – Proceed to Test Step 2. harness. Depending on the application, one or both of the terminating resistors may be located in other •...

  • Page 133: Data Link Circuit - Test

    This message will indicate that the version of the to diagnose other devices on the data link. software that is in the Perkins EST is not the same version of the software that is in the ECM. Install the Use the electronic service tool in order to clear all latest version of the Perkins EST software in order to rectify the fault.
  • Page 134 Schematic of the diagnostic connector and the Perkins Data Link connector g01208535 Illustration 37 Typical view of the P2 pin locations for the diagnostic and Perkins Data Link connectors (20) Perkins Data link (PDL) - (21) Perkins Data link (PDL) +...
  • Page 135 SENR9982-01 Troubleshooting Section g01208545 Illustration 38 Typical view of the P1 pin locations for the diagnostic and Perkins Data Link connectors (23) Perkins Data link (PDL) + (24) Perkins Data link (PDL) - Test Step 1. Inspect Electrical Connectors Results: and Wiring.
  • Page 136 Repair: Refer to Troubleshooting, “Engine Wiring Information”. Proceed to Test Step 2. g01244182 Illustration 39 Test Step 5. Check the Perkins Data Link Typical view of the 9 pin diagnostic connectorfrom the wire side Connections. (A) Switched battery + (B) Battery ground (GND) A.
  • Page 137 SENR9982-01 Troubleshooting Section Expected Result: G. If changing the Perkins EST cables does not allow the Perkins EST to operate correctly, connect The resistance that is measured is less than 10 another Perkins EST. Ohms. H. Turn the keyswitch to the ON position.
  • Page 138 SENR9982-01 Troubleshooting Section g01244183 Illustration 40 Schematic of the bypass harness connector...

  • Page 139: Digital Throttle Position Sensor Circuit - Test

    SENR9982-01 Troubleshooting Section g01184528 Illustration 41 Typical view of the P1 OEM connector pin locations for the diagnostic and Perkins data link connectors (1) Battery ground (GND) (9) Battery ground (GND) (21) J1939 (CAN) + (2) Battery ground (GND) (10) Battery ground (GND)
  • Page 140 PTO mode. The ECM is in PTO mode if the “PTO ON/OFF Switch” is ON. This can be checked with Perkins Electronic Service Tool (EST). Refer to Troubleshooting, “PTO Switch Circuit - Test” for testing if the PTO is being used.
  • Page 141 • P1:33 Codes • P1:43 A. Connect Perkins EST to the data link connector. • P1:53 B. Turn the keyswitch to the ON position. C. Check the screw for the ECM connector for the correct torque of 5.0 N·m (44 lb in).
  • Page 142 A. Access the active diagnostic code screen on • Result 1 – Proceed to Test Step 3. Perkins EST. Ensure that one of the following diagnostic code is active before proceeding: • Result 2 – Proceed to Test Step 5.
  • Page 143 Result 1 – The digital throttle position sensor is Temporarily install another digital throttle position operating correctly. Continue troubleshooting until sensor. Use the Perkins EST in order to check for the original condition is resolved. STOP. an active +8 V diagnostic code. Replace the digital throttle position sensor if both of the following •...
  • Page 144 If the battery voltage is correct, temporarily connect The duty cycle is between 10 and 22 percent with the a test ECM. Use Perkins EST to verify that the throttle pedal assembly in the low idle position, and active diagnostic code is resolved. If the fault is...
  • Page 145 SENR9982-01 Troubleshooting Section Expected Result: The duty cycle is between approximately 10 and 22 percent with the throttle pedal assembly in the low idle position, and the duty cycle is between 75 and 90 percent with the throttle pedal assembly in the high idle position.

  • Page 146: Ecm Memory - Test

    E. Turn the keyswitch to the ON position. A 0253-02 diagnostic code is active. F. Check the duty cycle of the digital throttle position sensor on Perkins EST while the digital throttle Results: pedal assembly is being moved over the full range.

  • Page 147: Electrical Connectors - Inspect

    SENR9982-01 Troubleshooting Section Test Step 1. Check Connectors for i02499732 Moisture and Corrosion Electrical Connectors - Inspect System Operation Description: Most electrical faults are caused by poor connections. The following procedure will assist in detecting faults in connectors and wiring. If a fault is found, correct the condition and verify that the fault is resolved.
  • Page 148 SENR9982-01 Troubleshooting Section B. Ensure that the sealing plugs are in place. If any If moisture or corrosion is evident in the connector, of the plugs are missing, replace the plug. Ensure the source of the moisture entry must be found that the plugs are inserted correctly into the and the source of the moisture entry must be connector.
  • Page 149 SENR9982-01 Troubleshooting Section Use the electronic service tool in order to clear all Results: logged diagnostic codes and then verify that the repair eliminates the fault. • OK – The terminals are OK. Proceed to Test Step STOP. • Not OK – The terminals of the connector are Test Step 2.
  • Page 150 SENR9982-01 Troubleshooting Section Test Step 6. Check the Locking • Not OK – A wire has been pulled from a terminal Mechanism of the Connectors or a terminal has been pulled from the connector. Repair: Use the CH11155 Crimp Tool to replace A.

  • Page 151: Engine Pressure Sensor Open Or Short Circuit - Test

    • 0100-04 Engine Oil Pressure Sensor voltage below A. Select the “Wiggle Test” from the diagnostic tests normal on the Perkins Electronic Service Tool (EST). • 0100-10 Engine Oil Pressure Sensor abnormal B. Choose the appropriate group of parameters to rate of change monitor.
  • Page 152 SENR9982-01 Troubleshooting Section If the sensor is disconnected at the sensor connector, the presence of pull-up voltage at the sensor connector indicates that the wires from the sensor connector to the ECM are not open or shorted to ground. If the sensor is disconnected at the sensor connector, the absence of pull-up voltage at the sensor connector indicates an open in the signal wire or a short to ground.
  • Page 153 SENR9982-01 Troubleshooting Section The troubleshooting procedures for the diagnostic codes of each pressure sensor are identical. The pressure sensors are active sensors. The pressure sensor has three terminals. Active sensors require supply voltage from the ECM. The ECM connector P2/J2 supplies +5 volts to terminal 1 of each sensor.
  • Page 154 F. Check the harness for abrasions and for pinch sensor connectors: points from the sensors back to the ECM. • P201 Engine Oil Pressure Sensor G. Use the Perkins EST to perform a “Wiggle Test”. The “Wiggle Test” will identify intermittent • P228 Fuel Rail Pressure Sensor connections.
  • Page 155 Proceed to Test Step 8. Test Step 5. Measure the Sensor Supply B. Use the Perkins EST to check for active diagnostic Voltage. codes. Record all active diagnostic codes. C. Determine if the fault is related to an open circuit A.
  • Page 156 3. If the diagnostic code is active replace the the engine. sensor. E. Use the Perkins EST to check for a short circuit 4. Use the electronic service tool in order to clear diagnostic code. The new sensor should be all logged diagnostic codes and then verify that connected to the harness at this time.
  • Page 157 E. Fabricate a jumper wire that is long enough to reach from the ECM to the sensor connector or Use Perkins EST to verify that there is a Voltage use an engine sensor harness bypass with 3 Above Normal diagnostic code.

  • Page 158: Engine Speed/Timing Sensor Circuit - Test

    SENR9982-01 Troubleshooting Section During normal operation, the secondary speed/timing i02491413 sensor is used to determine the cycle that the Engine Speed/Timing Sensor engine is on. When the timing has been established, Circuit - Test the primary speed/timing sensor is then used to determine the engine speed and the angular position.
  • Page 159 SENR9982-01 Troubleshooting Section Table 58 P2/J2 Pin Connections Function Crankshaft Primary Sensor Camshaft Secondary Sensor Sensor Pin +8 Volt Supply Signal g01245085 Illustration 58 The schematic for the speed/timing sensors g01188474 Illustration 59 Typical view of the speed/timing sensor pin locations (10) Speed/ Timing sensor supply (8v) (52) Crankshaft speed timing sensor signal (53) Pump/Cam speed sensor signal (Sig)
  • Page 160 SENR9982-01 Troubleshooting Section g01245086 Illustration 60 Typical view of the locations for the speed/timing sensor on the 1104D engine (1) Primary speed/timing sensor (2) Secondary speed/timing sensor...
  • Page 161 SENR9982-01 Troubleshooting Section g01249838 Illustration 61 Detailed view of the sensor locations on the 1104D engine (1) Primary crankshaft speed/timing sensor (2) Secondary speed/timing sensor g01188476 Illustration 62 Typical view of the sensor locations on the 1106D engine (1) Primary crankshaft speed/timing sensor (2) Secondary speed/timing sensor...
  • Page 162 SENR9982-01 Troubleshooting Section g01249863 Illustration 63 Detailed view of the sensor locations on the 1106D engine (1) Primary speed/timing sensor (crankshaft) (2) Secondary speed/timing sensor (camshaft) g01212995 Illustration 64 Typical example of the speed, crank and the fuel/camshaft speed sensors (1) Voltage Supply (8V) (2) Signal (Sig) Test Step 1.
  • Page 163 Use the electronic service tool in order to clear all D. Use the Perkins EST in order to monitor active logged diagnostic codes and then verify that the diagnostic codes or recently logged diagnostic repair has eliminated the fault.
  • Page 164 SENR9982-01 Troubleshooting Section D. Check the resistance between P2:10 to the Results: secondary speed/timing sensor terminal 1. The resistance should be less than 2.0 Ohms. • OK – There is no short circuit. Proceed to Test Step 7. Expected Result: •...
  • Page 165 • Lubricate the O ring with clean engine E. Start the engine. lubricating oil. F. Use the Perkins EST in order to monitor the • Ensure that the plug for the sensor has a seal diagnostic codes. inside the connector body. If a seal is damaged or missing, replace the seal.

  • Page 166: Engine Temperature Sensor Open Or Short Circuit - Test

    SENR9982-01 Troubleshooting Section The ECM continuously outputs a pull-up voltage i02494232 on the circuit for the sensor signal wire. The ECM Engine Temperature Sensor uses this pull-up voltage in order to detect an open Open or Short Circuit - Test in the signal circuit.
  • Page 167 B. Turn the keyswitch to the ON position. Note: Wait at least 30 seconds for activation of the diagnostic codes. C. Use the Perkins EST in order to verify if any of the following diagnostic codes are active or recently logged: •...
  • Page 168 E. Check the harness for abrasions and for pinch B. Access the “Active Diagnostic Code” screen on points from the sensor to the ECM. the Perkins EST and check for active diagnostic codes. Expected Result: C. Determine if the fault is related to an Voltage...
  • Page 169 An intermittent fault may exist. B. Turn the keyswitch to the ON position. Repair: By using the Perkins EST, perform a Note: Wait at least 10 seconds for the activation of “Wiggle Test”. If faults are indicated then go to the any diagnostic fault codes.
  • Page 170 P2:37 common connection C. Remove the sensor signal wire from the P2 for the sensors. Reassemble the P2 connector to the ECM. Use the Perkins EST in order to check connector. the diagnostic codes. Wait at least 10 seconds for activation of the Voltage Below Normal diagnostic D.

  • Page 171: Fuel Rail Pump Solenoid - Test

    H. Turn the keyswitch to the ON position. to service. STOP. • I. Use the Perkins EST in order to monitor the Not OK – At least one intermittent fault was “Active Diagnostic Code” screen for either the indicated.
  • Page 172 No fuel rail pressure can be observed on the status screen of the Perkins Electronic Service Tool (EST). g01245090...
  • Page 173 SENR9982-01 Troubleshooting Section Test Step 1. Inspect the Electrical C. Use the Perkins EST to verify if any of the following Connectors and the Harness diagnostic codes are active or recently logged: • 1779-05 Fuel Rail #1 Pressure Valve Solenoid current below normal Electrical shock hazard.
  • Page 174 The nominal resistance is less than 1 Ohm. C. Turn the keyswitch to the ON position. Results: D. Use the Perkins EST in order to perform the fuel rail pump solenoid test. • OK – There is an open circuit or there is an excessive resistance in the harness.
  • Page 175 SENR9982-01 Troubleshooting Section B. Disconnect the P532 connector from the fuel rail E. Use the Perkins EST in order to perform the fuel pump solenoid. rail pump solenoid test. C. Disconnect the P2 connector from the ECM. F. Use the Perkins EST in order to monitor the status screen.

  • Page 176: Idle Validation Switch Circuit - Test

    If the IVS operates outside of the programmed range then the engine speed may not respond to changes in the throttle position for the suspect throttle. The Perkins EST may be used for the following: • If necessary, reset the IVS threshold for an existing IVS.
  • Page 177 (44) Idle validation (IVS) 2 (45) Idle validation (IVS) 1 Test Step 1. Check the Operation of the C. Use the Perkins EST in order to check the current Idle Validation Switch (IVS) “Throttle Configuration”. A. Connect the Perkins EST to the diagnostic D.
  • Page 178 Repair: B. Turn the keyswitch to the ON position. Proceed to Test Step 7. C. Use the Perkins EST in order to check the current Test Step 3. Inspect Electrical Connectors “Throttle Configuration”. and the Harness D. Select the “SERVICE” option from the drop-down menu of the Perkins EST.
  • Page 179 Ensure that all of the seals are correctly in place and ensure F. Use the Perkins EST in order to monitor the IVS that the connectors are completely coupled. status. Note the status of the IVS.
  • Page 180 A. Turn the keyswitch to the OFF position. “Throttle Configuration” menu of the Perkins EST. B. Disconnect the IVS. D. Select the “Throttle status” function on the Perkins EST. Select “Status” function and then select C. Set the throttle to low idle.

  • Page 181: Ignition Keyswitch Circuit And Battery Supply Circuit - Test

    Switch (IVS) Threshold Limits by Using the Perkins Electronic Service Tool (EST) System Operation Description: The Perkins EST can be used to reset the “Idle This procedure tests that the correct voltage is being Validation Min OFF Threshold” and the “Idle supplied to the Electronic Control Module (ECM).
  • Page 182 Therefore, you will be able to power up the Perkins Electronic Service Tool (EST), but you may not be able to communicate with the engine ECM. The engine ECM requires the keyswitch to be in the ON position in order to maintain communications.
  • Page 183 SENR9982-01 Troubleshooting Section g01245123 Illustration 72 Schematic for the ignition keyswitch and battery supply circuit g01193796 Illustration 73 Typical rear view of the pin locations for the ignition keyswitch and battery supply circuit (1) Battery ground (GND) (9) Battery ground (GND) (2) Battery ground (GND) (10) Battery ground (GND) (3) Battery ground (GND)
  • Page 184 P1: 1, 2, 3, 9, 10 ( Battery) Expected Result: • P1:40 (keyswitch) One of the following diagnostic codes is active or C. Use the Perkins EST to perform a “Wiggle Test”. logged: Special attention must be paid to the following connections: •...
  • Page 185 SENR9982-01 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 (keyswitch) may be an effective means of determining the root and P1:10 (-Battery).
  • Page 186 SENR9982-01 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 187: Indicator Lamp Circuit - Test

    • The lamps are not operating correctly. E. Connect the Perkins EST to the diagnostic Also, use this procedure if another procedure has connector of the bypass harness and verify that directed you here.
  • Page 188 SENR9982-01 Troubleshooting Section g01245196 Illustration 75 Typical schematic of the indicator lamp circuit g01176466 Illustration 76 Typical example of the P1 OEM connector pin locations (1) Ground (GND) (7) Battery (+) (59) Warning lamp (2) Ground (GND) (8) Battery (+) (60) Stop lamp (3) Ground (GND) (15) Battery (+)
  • Page 189 ECM. A. Turn the keyswitch to the ON position. Repair: Repair the lamp circuit. B. Use the Perkins EST to select the “override” function in order to switch individual lamps ON and OFF.

  • Page 190: Injector Data Incorrect - Test

    F. Turn the keyswitch to the ON position. Use the • 0005-02 Cylinder #5 Injector erratic, intermittent, Perkins EST to select the override function in or incorrect (1106D engine only) order to switch individual lamps ON and OFF. •...
  • Page 191 D. Make a note of the logged diagnostic codes. Numbers Expected Result: A. Use the Perkins EST in order to make a note of the logged diagnostic codes. Expected Result 1 B. Use the noted diagnostic codes in order to check One or more of the following diagnostic codes are the cylinders for faulty injectors.

  • Page 192: Injector Solenoid Circuit - Test

    0004-06 Cylinder #4 Injector current above normal Refer to Troubleshooting, “Replacing the ECM”. • 0005-05 Cylinder #5 Injector current below normal B. Use the Perkins EST in order to perform the “Fuel (C6.6 engine only) System Verification - Test.”. Verify that the test eliminates the fault.
  • Page 193 The “Injector Solenoid Test” will send a signal to each solenoid. The Perkins EST will indicate the status of the solenoid as “OK”, “Open”, or “Short”.
  • Page 194 SENR9982-01 Troubleshooting Section g01245541 Illustration 79 Schematic for the injector solenoid circuit for the 1104D engine g01253098 Illustration 80 P2 pin connections for the 1104D engine (57) Injector Cylinder (Number 1) (64) Injector Cylinder (Number 3) (35) Injector Cylinder (Number 1 Return) (8) Injector Cylinder (Number 3 Return) (63) Injector Cylinder (Number 2) (58) Injector Cylinder (Number 4)
  • Page 195 SENR9982-01 Troubleshooting Section g01245542 Illustration 81 Schematic for the injector solenoid circuit for the 1106D engine g01171366 Illustration 82 P2 pin connections for the 1106D engine (57) Injector Cylinder (Number 1) (59) Injector Cylinder (Number 3) (63) Injector Cylinder (Number 5) (35) Injector Cylinder (Number 1 Return) (33) Injector Cylinder (Number 3 Return) (7) Injector Cylinder (Number 5 Return)
  • Page 196 SENR9982-01 Troubleshooting Section g01245543 Illustration 83 Typical example of the fuel injector harness connector g01245544 Illustration 84 Typical example of the connector on the valve mechanism cover Test Step 1. Inspect Electrical Connectors E. Check the harness and wiring for abrasion and for and Wiring pinch points from the injectors to the ECM.
  • Page 197 Codes that are Related to the Injector E. Access the “Injector Solenoid Test” by accessing Solenoids the following display screens in order: • “Diagnostics” A. Connect the Perkins EST to the diagnostic connector. • “Diagnostic Tests” B. Turn the keyswitch to the ON position. •...
  • Page 198 D. Select the start button at the bottom of the screen terminals on both ends of the wire. for the cylinder cutout test on the Perkins EST. E. Insert one end of the jumper wire into the terminal E. Select the “Cylinder Cutout Test”.
  • Page 199 Results: Expected Result: • Perkins EST displays “Current Above Normal” for the OK – There is a fault with the injector harness cylinder with the jumper wire. under the valve cover. Repair: Repair the injector harness or replace the Note: On four cylinder engines, shorting a shared injector harness under the valve cover.
  • Page 200 SENR9982-01 Troubleshooting Section Use the electronic service tool in order to clear all • Not OK – One or more cylinders indicate “Current logged diagnostic codes and then verify that the Above Normal”. Note the cylinders that indicate repair eliminates the fault. “Current Above Normal”.
  • Page 201 SENR9982-01 Troubleshooting Section If the test ECM fixes the fault, reconnect the Use the electronic service tool to clear all logged suspect ECM. diagnostic codes and then verify that the repair has eliminated the fault. If the fault returns with the suspect ECM, replace the ECM.

  • Page 202: Mode Selection Circuit - Test

    SENR9982-01 Troubleshooting Section Use the electronic service tool to clear all logged diagnostic codes and then perform the “Injector Solenoid Test” in order to verify that the repair eliminates the fault. STOP. i02500248 Mode Selection Circuit - Test System Operation Description: Use this procedure under the following circumstances: •...
  • Page 203 SENR9982-01 Troubleshooting Section Table 60 Switch 2 Switch 1 Mode 1106D Engine Rating Droop (%) Number Throttle 1 Throttle Torque Speed Control Open Open 100 KW @ 2200 RPM Open Closed 100 KW @ 2200 RPM Closed Open 120 KW @2200 RPM Closed Closed 120 KW @ 2200 RPM...
  • Page 204 C. Turn the keyswitch to the ON position. E. Check the harness for abrasions and for pinch D. Monitor the status screen on the Perkins EST. points from the battery to the ECM. Cycle the mode switch to the ON position and to the OFF position.
  • Page 205 When the connections are removed from the P1 the Wire Harness at the ECM OEM connector, the mode switch indication on the Perkins EST will be in the OFF position. The switch A. Turn the keyswitch to the OFF position. will indicate an open condition.

  • Page 206: Pto Switch Circuit - Test

    SENR9982-01 Troubleshooting Section Repair: If the fault has not been eliminated An indicator lamp is used to indicate the status of temporarily connect a test ECM. Remove all the PTO. jumpers and replace all connectors. The test ECM should be programmed with the correct software. All parameters should be set to the same value of the suspect ECM.
  • Page 207 SENR9982-01 Troubleshooting Section g01245654 Illustration 87 Schematic for the PTO switches g01187525 Illustration 88 Typical view of the PTO switch pin locationson the P1 connector (35) Switch Ground (GND) (50) PTO mode - raise/resume (52) PTO mode - ON/OFF (49) PTO mode - disengage (51) PTO mode - set/lower Test Step 1.
  • Page 208 C. Turn the keyswitch to the ON position. D. Observe the status of the PTO mode switch on the A. Use the Perkins EST in order to observe the Perkins EST while you operate the “PTO ON/OFF switch status while the PTO mode disengage switch”...
  • Page 209 Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the D. Monitor the status screen on the Perkins EST repair has eliminated the fault. while the jumper wire is being disconnected and reconnected.

  • Page 210: Starting Aid (Glow Plug) Relay Circuit - Test

    Starting aids may be used if the engine has previously been started. The “Wait to Start” lamp will not be active in these conditions. Perkins Electronic Service Tool (EST) Test Aid The Perkins Electronic Service Tool (EST) includes the test “Glow Plug Start Aid Override Test”. The “Glow Plug Start Aid Override Test”...
  • Page 211 SENR9982-01 Troubleshooting Section g01245657 Illustration 89 Typical schematic for the starting aid switch g01205132 Illustration 90 Typical view of the P1 OEM connector pin locations (1) Ground (GND) (9) Ground (GND) (63) Cold start lamp (2) Ground (GND) (10) Ground (GND) (3) Ground (GND) (57) Start aid control...
  • Page 212 SENR9982-01 Troubleshooting Section Test Step 1. Inspect Electrical Connectors C. Use the Perkins EST to select the “Glow Plug and Wiring Override Test” in order to turn on the power for the glow plugs. A. Inspect the following connectors: D. Check for active diagnostic codes or recently •...

  • Page 213: Throttle Switch Circuit - Test

    C. Connect a jumper wire between the battery ground E. Use the Perkins EST in order to perform a “Glow Plug Override Test”. and terminal “D” on the glow plug start aid relay.
  • Page 214 SENR9982-01 Troubleshooting Section • There is an active diagnostic code or a recently logged diagnostic code that is related to the following: • 0091-02 Throttle Position Sensor erratic, intermittent, or incorrect • 0774-02 Secondary Throttle Position Sensor erratic, intermittent, or incorrect Check that the software configuration on the Electronic Control Module (ECM) is correct for a multi-position throttle.
  • Page 215 ECM connector that are associated with the active diagnostic code. Refer to illustration 92. A. Connect Perkins Electronic Service Tool (EST) at the diagnostic connector. D. Verify that the latch tab of the connector is correctly latched.
  • Page 216 Not OK – There is a short in the harness between B. Observe the status of the suspect throttle input on the ECM and the throttle switch. Perkins EST. Repair: Repair the circuit. C. Use a suitable jumper wire to short P503:1 to the...

  • Page 217: Wastegate Solenoid - Test

    K. Observe the status of the suspect throttle input on Perkins EST. The control system for the electronically controlled wastegate precisely regulates the intake manifold L. Turn the keyswitch to the OFF position.
  • Page 218 SENR9982-01 Troubleshooting Section Table 62 Pin Connections Function Sensor Pin P2 Pin Connection Ground Signal g01245700 Illustration 93 Schematic for the wastegate g01245711 Illustration 94 Wastegate connector (1) Ground (GND) (2) Signal (SIG)
  • Page 219 A. Turn the keyswitch to the OFF position. wires that are associated with the wastegate solenoid. B. Connect the Perkins Electronic Service Tool (EST) C. Check the screw for the ECM connector for the to the data link connector. correct torque of 5.0 N·m (44 lb in).
  • Page 220 30 seconds in order for the result to be displayed. coupled. E. Check for active diagnostic codes on the Perkins Use the electronic service tool in order to clear all EST. logged diagnostic codes and then verify that the repair eliminates the fault.
  • Page 221 Perkins EST. Activate the “Turbo Wastegate • OK – Diagnostic code 526-5 is now active. Solenoid Output” on the Perkins EST. Wait at least 30 seconds for activation of the diagnostic codes. Repair: There is a short in the solenoid.
  • Page 222 SENR9982-01 Troubleshooting Section 2. If the test ECM eliminates the fault, reconnect the suspect ECM. If the fault returns, permanently install the replacement ECM. STOP.

  • Page 223: Index

    SENR9982-01 Index Section Index CID 0100 FMI 04 ........... 95 Numerics CID 0100 FMI 10 ........... 95 5 Volt Sensor Supply Circuit - Test ....... 118 CID 0110 FMI 03 ........... 96 CID 0110 FMI 04 ........... 96 CID 0168 FMI 00 ........... 96 CID 0168 FMI 01 ...........
  • Page 224 Electronic Service Tools ........12 Fuel Rail Pump Solenoid - Test ......171 Optional Service Tools ........12 Perkins Electronic Service Tool......13 Required Service Tools ........12 Electronic Troubleshooting ........5 Engine Cranks but Will Not Start ......53 Glossary ..............
  • Page 225 SENR9982-01 Index Section Intermittent Engine Shutdown ....... 71 Probable Causes ..........71 Recommended Actions........71 Self-Diagnostics............. 18 Intermittent Low Power or Power Cutout....72 Sensors and Electrical Connectors ....... 18 Probable Causes ..........72 Starting Aid (Glow Plug) Relay Circuit - Test ..210 Recommended Actions........
  • Page 226 SENR9982-01 Index Section...
  • Page 227 SENR9982-01 Index Section...
  • Page 228 Copyright © 2006 Perkins Engines Company Limited All Rights Reserved Printed in U.K.

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