Perkins 1106D Troubleshooting Manual
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Perkins 1106D Troubleshooting Manual

Electric power generation
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KENR6201-01
February 2010
Troubleshooting
1106D Electric Power Generation
(EPG)
PJ (Engine)
This document is printed from SPI². Not for RESALE

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Do you have a question about the 1106D and is the answer not in the manual?

Questions and answers

Gilbert
March 11, 2025

Water in Exhaust I replaced cylinder head, head gasket and &after cooler

0
3 comments:
Gilbert KABERA
March 11, 2025

@Gilbert and the problem is the sam

0
Mr. Anderson
March 11, 2025

Possible causes of water in the exhaust of a Perkins 1106D after replacing the cylinder head, head gasket, and aftercooler include:

- Faulty cylinder head gasket installation.
- Cracked or damaged cylinder head.
- Coolant entering the combustion chamber due to leaks.
- Residual coolant in the exhaust system from previous issues.
- Improper sealing of the aftercooler allowing coolant leakage.

Check for coolant leaks, re-inspect the gasket installation, and verify the integrity of the cylinder head and aftercooler.

This answer is automatically generated

0
Gilbert KABERA
March 11, 2025

Sorry it's 1106C But the cylinder head, head gasket and after are brand new.

0

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Summary of Contents for Perkins 1106D

  • Page 1 KENR6201-01 February 2010 Troubleshooting 1106D Electric Power Generation (EPG) PJ (Engine) This document is printed from SPI². Not for RESALE...
  • 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

    KENR6201-01 Table of Contents Table of Contents Troubleshooting with a Diagnostic Code Diagnostic Code Cross Reference ....... 68 CID 0001 FMI 02 ..........70 CID 0001 FMI 05 ..........70 Troubleshooting Section CID 0001 FMI 06 ..........71 CID 0001 FMI 07 ..........71 Electronic Troubleshooting CID 0002 FMI 02 ..........
  • Page 4 KENR6201-01 Table of Contents E085 Engine Shutdown Overridden ..... 94 E255 Diagnostic Reset ......... 94 E264 Emergency Stop Activated ......94 E360 Low Engine Oil Pressure ......95 E361 High Engine Coolant Temperature ....96 E362 Engine Overspeed ........97 E396 High Fuel Rail Pressure ......

  • Page 5: Troubleshooting Section

    KENR6201-01 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i03805210 System Overview System Operation g01808033 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 KENR6201-01 Troubleshooting Section The 1106D engine was designed for electronic At start-up, the ECM determines the top center control. The engine has an Electronic Control Module position of the number 1 cylinder from the secondary (ECM), a fuel rail pump and electronic unit injectors.

  • Page 7: 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 8 KENR6201-01 Troubleshooting Section Diagnostic Code – A diagnostic code is sometimes Event Code – An event code may be activated in order to indicate an abnormal engine operating referred to as a fault code. These codes indicate an electronic system malfunction. condition.
  • Page 9 KENR6201-01 Troubleshooting Section Hertz (Hz) – Hertz is the measure of electrical FRC – See “Fuel Ratio Control”. frequency in cycles per second. Fuel Pump – See “Fuel Rail Pump”. High Pressure Fuel Rail Pump – See “Fuel Rail Fuel Rail – This item is sometimes referred to as Pump”.
  • Page 10 KENR6201-01 Troubleshooting Section Open Circuit – An open circuit is a condition that is Rated Fuel Limit – This is a limit that is based on caused by an open switch, or by an electrical wire the power rating of the engine and on the engine rpm. or a connection that is broken.

  • Page 11: Electronic Service Tools

    Perkins Electronic Service Tool i02517580 Electronic Service Tools The Perkins Electronic Service Tool can display the following information: • Status of all pressure sensors and temperature Perkins electronic service tools are designed to help...
  • Page 12 Communication Adapter (Electronic 27610251 Service Tool to ECM interface) 27610164 Adapter Cable As Refer to Perkins Engine Company Limited. Note: For more information regarding the use of the g01121866 Illustration 3 Electronic Service Tool and the PC requirements for the Electronic Service Tool, refer to the...

  • Page 13: Indicator Lamps

    KENR6201-01 Troubleshooting Section On – The lamp will come on when a “high coolant i03787449 temperature” event is detected. The “Warning” lamp Indicator Lamps and the “Shutdown” lamp may also come on. Overspeed Lamp Indicator Lamps Lamp check – When the keyswitch is turned to the ON position, the lamp will come on for two The functions of the indicator lamps are designed to seconds.
  • Page 14 KENR6201-01 Troubleshooting Section Operation of the Indicator Lamps Table 4 Warning Diagnostic Derate Shutdown Lamp State Description of the Indication Engine State Lamp Lamp Lamp Lamp (Alert (Action Lamp) Lamp) Lamp Check When the keyswitch is switched on, The keyswitch is the lamps come on for a period of on but the engine 2 seconds and the lamps will then...
  • Page 15 KENR6201-01 Troubleshooting Section (Table 4, contd) Derate If the derate lamp comes on The engine (Diagnostic during engine operation, and is operating. and Derate) the diagnostic lamp is flashing, However, an the lamps indicate that an active active diagnostic Flashing diagnostic code (an electrical fault) code is causing is present.

  • Page 16: Replacing The Ecm

    Note: If an ECM is intended to be used as a test the PTMI data on the Perkins intranet. ECM, “Test ECM Mode” must be selected on the electronic service tool before the engine serial 4.

  • Page 17: Self-Diagnostics

    KENR6201-01 Troubleshooting Section • 8. Download the flash file. Logged a. Connect the electronic service tool to the Active Code – An active diagnostic code indicates diagnostic connector. that an active fault has been detected by the control system. Active codes require immediate attention. b.
  • Page 18 KENR6201-01 Troubleshooting Section g01811780 Illustration 5 Sensor locations (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...
  • Page 19 KENR6201-01 Troubleshooting Section g01811835 Illustration 6 Detailed views of the sensor locations This document is printed from SPI². Not for RESALE...
  • Page 20 KENR6201-01 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 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 KENR6201-01 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 KENR6201-01 Troubleshooting Section Schematic Diagrams g01782875 Illustration 8 Schematic Diagram for the Engine Harness This document is printed from SPI². Not for RESALE...

  • Page 24: Ecm Harness Connector Terminals

    KENR6201-01 Troubleshooting Section g02047353 Illustration 9 Schematic Diagram for a Typical Application i03434106 ECM Harness Connector Terminals The Electronic Control Module (ECM) uses connectors that have 64 terminals to interface to the wiring harness. g01784773 Illustration 10 Layout of the Connector Pins (view from the rear) This document is printed from SPI².
  • Page 25 KENR6201-01 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

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

  • Page 27: Flash Programming

    Injector Trim File Note: If you do not have the part number for the flash file, use “PTMI” on the Perkins Intranet. Note: You must have the engine serial number in The electronic service tool is used to load the injector order to search for the part number for the flash file.

  • Page 28: Speed Demand Input Setup

    Note: The serial number for the electronic unit injector and the confirmation code number for the The 1106D engine can have a digital input that electronic unit injector are located on the electronic uses a Pulse Width Modulated (PWM) signal, an unit injector.
  • Page 29 KENR6201-01 Troubleshooting Section Table 9 Range Default 0 to 100 percent 0 percent Lower Position Limit This is the minimum throttle percentage that will be interpreted by the ECM as zero throttle. This parameter is used with the value of initial lower position limit to make an allowance for manufacturing tolerances between different speed demand input devices.
  • Page 30 KENR6201-01 Troubleshooting Section Table 13 Range Default 0 to 100 percent 0 percent Lower Dead Zone This is a throttle range above the initial lower position limit before the engine will increase in rpm. Table 14 Range Default 0 to 100 percent 0 percent Upper Dead Zone This is a throttle range that is below the initial upper...

  • Page 31: Customer Specified Parameters

    KENR6201-01 Troubleshooting Section Customer Specified Table 17 Parameters Value Default 17 digits The available characters are dependent on the Not programmed i03807232 service tool that is Customer Specified being used. Parameters Throttle Lock Parameters Throttle Lock Feature Installation Status Customer specified parameters allow the engine to be configured to the exact needs of the application.
  • Page 32 KENR6201-01 Troubleshooting Section Miscellaneous Configurable Governor Droop “Configurable Governor Droop” allows the engine to Monitoring Mode Shutdowns run in “droop mode” when the genset is operated in parallel with other gensets. “Monitoring Mode Shutdowns” controls the shutdown feature that is associated with the engine monitoring Table 24 feature.
  • Page 33 KENR6201-01 Troubleshooting Section Table 27 Value Default Disabled Disabled Enabled User Defined Switch Installation Status A user defined shutdown switch is an optional switch input. Programming the “User Defined Switch Installation Status” parameter to “Enabled” notifies the ECM that a user defined switch input is present on pin J1:48.

  • Page 34: Customer Specified Parameters Table

    KENR6201-01 Troubleshooting Section i02444244 Customer Specified Parameters Table Table 29 Customer Specified Parameters ECM Parameter Possible Values Default Value Engine Rating Parameter “Rating Number” 1 to 4 ECM Identification Parameter “Equipment ID” 17 Digits Not Programmed Available characters are dependent on the service tool that is used Throttle Lock Parameters “Throttle Lock Feature Installation...

  • Page 35: Customer Specified Parameters Worksheet

    KENR6201-01 Troubleshooting Section i02444245 Customer Specified Parameters Worksheet Table 30 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 36: System Configuration Parameters

    KENR6201-01 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: i03818369 pistons, fuel injectors, and other components.

  • Page 37: Troubleshooting Without A Diagnostic Code

    KENR6201-01 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 i03858309 Disassembly and Assembly, “Alternator - Remove”...

  • Page 38: Battery

    KENR6201-01 Troubleshooting Section Alternator i03807352 Can Not Reach Top Engine Verify that the alternator is operating correctly. Refer to Systems Operation, Testing and Adjusting, “Alternator - Test”. The alternator is not a serviceable item. If the alternator is not operating correctly, the alternator must be replaced.
  • Page 39 KENR6201-01 Troubleshooting Section 7. If the repairs have not eliminated the faults 3. Check that the compressor housing for the proceed to “Throttle Signal for the Speed Demand turbocharger is free of dirt, debris and damage. Input”. 4. Check that the turbine housing for the turbocharger is free of dirt, debris and damage.

  • Page 40: Coolant In Engine Oil

    KENR6201-01 Troubleshooting Section Individual Malfunctioning Cylinders 10. Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, “Fuel System Pressure - Test”. 1. With the engine speed at a fast idle, use the electronic service tool to isolate one cylinder at a time.

  • Page 41: Coolant Temperature Is Too High

    KENR6201-01 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 42: Ecm Will Not Accept Factory Passwords

    KENR6201-01 Troubleshooting Section Coolant Level 3. Check the engine cooling fan for damage. If necessary, replace the fan. Refer to Disassembly 1. Inspect the coolant level. If necessary, add and Assembly, “Fan - Remove and Install”. coolant. Coolant Pump 2. Check the cooling system for leaks. Repair any leaks immediately.

  • Page 43: Ecm Will Not Communicate With Other Systems Or Display Modules

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

  • Page 44: Engine Cranks But Will Not Start

    KENR6201-01 Troubleshooting Section Communication Adapter and/or Cables i03807671 Engine Cranks but Will Not 1. Make sure that the firmware and driver files are Start the most current files that are available for the type of communication adapter that is being used. If the firmware and driver files do not match, the communication adapter will not communicate with the electronic service tool.
  • Page 45 KENR6201-01 Troubleshooting Section • 3. Attempt to start the engine. If the engine will not If the ambient temperature is below 0 °C (32 °F), start, proceed to “Visible Faults”. make sure that the correct specification of engine oil and oil for the machine is used. Display on the Control Panel •...
  • Page 46 KENR6201-01 Troubleshooting Section 6. Attempt to start the engine. If the engine will not b. If the signal from the secondary speed/timing start, proceed to “Low Pressure Fuel System”. sensor is 0 rpm, investigate the secondary speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor Circuit - Test”.
  • Page 47 3. Attempt to start the engine. If the engine will not Troubleshooting, “Flash Programming”. start, proceed to “Valve Lash”. e. Contact Perkins Global Technical Support. Valve Lash Note: This consultation can greatly reduce the repair 1. Check the valve lash. Refer to Systems Operation, time.

  • Page 48: Engine Has Early Wear

    KENR6201-01 Troubleshooting Section Possible causes of low compression are shown Make sure that the engine is maintained at the in the following list: correct maintenance intervals. Refer to the Operation and Maintenance Manual, “Maintenance Interval • Loose glow plugs Schedule”. •...

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

    KENR6201-01 Troubleshooting Section Air Intake and Exhaust System i03818598 Engine Misfires, Runs Rough 1. Check the air filter restriction indicator, if equipped. or Is Unstable 2. Ensure that the air filter is clean and serviceable. 3. Check the air intake and exhaust systems for the following defects: The probable root causes are listed in order below: •...

  • Page 50: Engine Oil In Cooling System

    KENR6201-01 Troubleshooting Section Individual Malfunctioning Cylinders 9. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel - Test”. 1. With the engine speed at a fast idle, use the electronic service tool to isolate one cylinder at 10.

  • Page 51: Engine Vibration

    KENR6201-01 Troubleshooting Section Probable Causes Cylinder Block • Engine oil cooler Inspect the top face of the cylinder block for faults and signs of leakage. If a fault is found, replace • Cylinder head gasket the cylinder block. If signs of leakage are found, determine the cause of the leakage.

  • Page 52: Engine Will Not Crank

    KENR6201-01 Troubleshooting Section Malfunctioning Individual Cylinder Ensure that the repairs have eliminated the fault. If the vibration is still present proceed to “Engine Supports”. 1. With the engine speed at a fast idle, use the electronic service tool to isolate one cylinder at a time.

  • Page 53: Excessive Black Smoke

    KENR6201-01 Troubleshooting Section Internal Engine Fault • Starting motor and/or flywheel ring gear • Electrical power supply 1. Remove the glow plugs. Refer to Disassembly and Assembly, “Glow Plugs - Remove and Install”. • Internal engine fault 2. Attempt to rotate the crankshaft through 360 •...
  • Page 54 KENR6201-01 Troubleshooting Section Recommended Actions Turbocharger Note: The turbocharger that is installed on this Diagnostic Codes engine is a nonserviceable item. If any mechanical fault exists, then the turbocharger must be replaced. Check for active diagnostic codes on the electronic service tool.

  • Page 55: Excessive Engine Oil Consumption

    KENR6201-01 Troubleshooting Section • Damaged cylinder head i03443800 Excessive Engine Oil 3. Perform all necessary repairs. Consumption 4. Ensure that the repairs have eliminated the fault. 5. If the repair does not eliminate the fault refer to “Electronic Unit Injectors”. Probable Causes Electronic Unit Injectors •...

  • Page 56: Excessive Fuel Consumption

    KENR6201-01 Troubleshooting Section Oil Level Low Compression (cylinder pressure) 1. Check the oil level in the engine. 1. Perform a compression test. Refer to Systems Operation, Testing and Adjusting, “Compression 2. If the oil level is high, check for contamination - Test ”.
  • Page 57 KENR6201-01 Troubleshooting Section Recommended Actions 2. If the engine operating temperature is low, check the operation of the water temperature regulator. If the water temperature regulator does not operate Fuel Quality correctly, a new water temperature regulator must be installed. Refer to Disassembly and Assembly, 1.

  • Page 58: Excessive Valve Lash

    KENR6201-01 Troubleshooting Section • Refer to the Troubleshooting Guide, “Excessive Valve Rocker arms Lash”. • Valve bridges Failure of the Primary Speed/Timing • Pushrods Sensor • Valve lifters If the primary speed/timing sensor fails, the engine will continue to operate using the signal from the •...

  • Page 59: Intake Air Temperature Is Too High

    KENR6201-01 Troubleshooting Section • 2. Monitor the display screen on the electronic Faulty piston service tool in order to verify the presence of active • diagnostic codes for the coolant temperature. Faulty piston rings Refer to Troubleshooting, “Engine Temperature • Sensor Open or Short Circuit - Test”.
  • Page 60 Measure the intake manifold pressure while the charge cooler is not obstructed. engine is operating under load. For specific data, refer to the Perkins Technical Marketing Information 2. Inspect the air charge cooler for contamination for the engine. and/or bent fins or damaged fins.

  • Page 61: Intermittent Engine Shutdown

    KENR6201-01 Troubleshooting Section a. If oil is found in the inlet to the turbocharger 3. Use the electronic service tool to check for compressor housing, the oil originates from the the following logged diagnostic code: 253-2 engine crankcase breather. “Personality Module mismatch”. If this diagnostic code is logged, proceed to Troubleshooting, b.

  • Page 62: Intermittent Low Power Or Power Cutout

    KENR6201-01 Troubleshooting Section 3. Verify the correct pin positions for the power i03809069 connections and the ground connections for the Intermittent Low Power or ECM. Power Cutout 4. If a fault is suspected with the ECM power and ground connections refer to Troubleshooting, “Ignition Keyswitch Circuit and Battery Supply Circuit - Test”.

  • Page 63: Low Engine Oil Pressure

    KENR6201-01 Troubleshooting Section Intake Manifold Pressure 2. If the fault is still apparent, proceed to “Oil Specification”. 1. Use the electronic service tool to verify the intake manifold pressure. Oil Specification 2. Turn the start switch to the ON position. 1.

  • Page 64: Low Power

    KENR6201-01 Troubleshooting Section • 2. If no damage is found, proceed to “Engine Oil Valve lash Suction Tube”. • Turbocharger Engine Oil Suction Tube • Fuel supply 1. Check the inlet screen on the oil suction tube • Low compression (cylinder pressure) and remove any material that may be restricting oil flow.
  • Page 65 KENR6201-01 Troubleshooting Section 4. Run the engine until the speed is equal to the 5. Check that the turbine blades rotate freely in the maximum no-load speed. turbocharger. 5. If the maximum no-load speed of the engine is 6. Ensure that the wastegate on the turbocharger is erratic refer to Troubleshooting, “Speed Demand adjusted correctly.

  • Page 66: Mechanical Noise (Knock) In Engine

    KENR6201-01 Troubleshooting Section Low Compression (Cylinder Pressure) Individual Malfunctioning Cylinders 1. Perform a compression test. Refer to Systems 1. With the engine speed at a fast idle, use the Operation, Testing and Adjusting, “Compression electronic service tool to isolate one cylinder at - Test ”.

  • Page 67: Noise Coming From Cylinder

    KENR6201-01 Troubleshooting Section Pistons Valve Lash 1. Inspect the pistons for damage and wear. Replace 1. Refer to Troubleshooting, “Excessive Valve Lash”. any damaged parts. 2. If the fault has not been eliminated, proceed to 2. If the mechanical noise is still apparent, refer to “Electronic Unit Injectors”.

  • Page 68: Troubleshooting With A Diagnostic Code

    KENR6201-01 Troubleshooting Section Troubleshooting with a Diagnostic Code i03809150 Diagnostic Code Cross Reference Table 31 3rd Party Device Flash CDL Code Description J1939 Code Code 0001-02 Cylinder #1 Injector Data Incorrect 651-2 0001-05 Cylinder #1 Injector open circuit 651-5 0001-06 Cylinder #1 Injector short 651-6 0001-07...
  • Page 69 KENR6201-01 Troubleshooting Section (Table 31, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code 0100-10 Engine Oil Pressure Sensor abmormal rate of change 100-10 0110-03 110-03 Engine Coolant Temperature open/short to +batt 0110-04 Engine Coolant Temperature short to ground 110-04 0168-00 System Voltage High...

  • Page 70: Cid 0001 Fmi 02

    KENR6201-01 Troubleshooting Section (Table 31, contd) 3rd Party Device Flash CDL Code Description J1939 Code Code E361-3 High Engine Coolant Temperature - Shutdown 110-00 E362-1 190-15 Engine Overspeed - Warning E362-3 Engine Overspeed - Sutdown 190-00 E396-2 High Fuel Rail Pressure 157-15 E398-2 Low Fuel Rail Pressure...

  • Page 71: Cid 0001 Fmi 06

    KENR6201-01 Troubleshooting Section The ECM will continue to attempt to operate the Results: electronic unit injector after the diagnostic code has • been logged but an open circuit will prevent the OK – STOP. operation of the electronic unit injector. i03795297 Perform the following diagnostic procedure: “Injector CID 0001 FMI 07...

  • Page 72: Cid 0002 Fmi 05

    KENR6201-01 Troubleshooting Section • No 0041 diagnostic codes are active. An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring • No 0262 diagnostic codes are active. that is unique to the electronic unit injector will prevent that individual electronic unit injector from operating.

  • Page 73: Cid 0002 Fmi 07

    KENR6201-01 Troubleshooting Section • The ECM will continue to attempt to operate the Data from the electronic unit injector for the No. 3 electronic unit injector after the diagnostic code cylinder is out of limits. has been logged but a short circuit will prevent the •...

  • Page 74: Cid 0003 Fmi 06

    KENR6201-01 Troubleshooting Section Possible Performance Effect: Troubleshooting: The engine will have low power and/or rough running. When the “Injector Cutout Test” is performed, a faulty electronic unit injector will indicate a low reading in Troubleshooting: comparison with the other electronic unit injectors. When the “Injector Cutout Test”...

  • Page 75: Cid 0004 Fmi 02

    KENR6201-01 Troubleshooting Section Results: i03797011 CID 0004 FMI 05 • OK – STOP. i03797010 Conditions Which Generate This Code: CID 0004 FMI 02 This diagnostic code indicates an open circuit (low current) in either the solenoid or the wiring for the electronic unit injector for No.

  • Page 76: Cid 0004 Fmi 06

    KENR6201-01 Troubleshooting Section i03797012 i03797013 CID 0004 FMI 06 CID 0004 FMI 07 Conditions Which Generate This Code: Conditions Which Generate This Code: This diagnostic code indicates a short circuit (high The electronic unit injector is no longer capable of current) in either the solenoid or the wiring for the delivering the correct amount of fuel.

  • Page 77: Cid 0005 Fmi 05

    KENR6201-01 Troubleshooting Section • Diagnostic code 190-08 is not active. An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring • No 0110 diagnostic codes are active. that is unique to the electronic unit injector will prevent that individual electronic unit injector from operating.

  • Page 78: Cid 0005 Fmi 07

    KENR6201-01 Troubleshooting Section • The ECM will continue to attempt to operate the Data from the electronic unit injector for the No. 6 electronic unit injector after the diagnostic code cylinder is out of limits. has been logged but a short circuit will prevent the •...

  • Page 79: Cid 0006 Fmi 06

    KENR6201-01 Troubleshooting Section Possible Performance Effect: Troubleshooting: The engine will have low power and/or rough running. When the “Injector Cutout Test” is performed, a faulty electronic unit injector will indicate a low reading in Troubleshooting: comparison with the other electronic unit injectors. When the “Injector Cutout Test”...

  • Page 80: Cid 0041 Fmi 03

    KENR6201-01 Troubleshooting Section • Results: Diagnostic code 168-01 is not active at the same time. • OK – STOP. System Response: i03797073 The ECM will log the diagnostic code. If equipped, CID 0041 FMI 03 the diagnostic lamp will flash. An active diagnostic code may not cause any noticeable effect on engine response unless the voltage drops below 6.5 VDC.

  • Page 81: Cid 0100 Fmi 03

    KENR6201-01 Troubleshooting Section Troubleshooting: i03797131 CID 0100 FMI 04 This diagnostic code indicates that the frequency of a digital throttle signal is out of the normal range. Perform the following diagnostic procedure: “Speed Conditions Which Generate This Code: Control (PWM) - Test” The Electronic Control Module (ECM) detects the Results: following conditions:...

  • Page 82: Cid 0110 Fmi 03

    KENR6201-01 Troubleshooting Section • The engine oil pressure signal is within the limits of The ECM will default to 90 °C (194 °F) for engine 410 kPa (59 psi) to 520 kPa (75 psi) with a pressure coolant temperature. “Voltage Above Normal” will variation of less than 1.68 kPa (0.25 psi)for more be displayed next to the status for “Engine Coolant than 30 seconds.

  • Page 83: Cid 0168 Fmi 00

    KENR6201-01 Troubleshooting Section • White smoke i03797318 CID 0168 FMI 01 Troubleshooting: The diagnostic code will detect an excessively low voltage from the engine coolant temperature sensor. Conditions Which Generate This Code: Perform the following diagnostic procedure: “Engine This code indicates that the battery circuit for the Temperature Sensor Open or Short Circuit - Test”...

  • Page 84: Cid 0168 Fmi 02

    KENR6201-01 Troubleshooting Section i03797330 i03797369 CID 0168 FMI 02 CID 0172 FMI 03 Conditions Which Generate This Code: Conditions Which Generate This Code: This condition indicates that the battery circuit for the The Electronic Control Module (ECM) detects the Electronic Control Module (ECM) is intermittent while following conditions: the engine is running.

  • Page 85: Cid 0172 Fmi 04

    KENR6201-01 Troubleshooting Section i03797372 i03797393 CID 0172 FMI 04 CID 0190 FMI 08 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 86: Cid 0253 Fmi 02

    KENR6201-01 Troubleshooting Section System Response: i03797609 CID 0261 FMI 11 If equipped, the diagnostic lamp will flash. The diagnostic code will be logged. Some system functions may not operate correctly. Conditions Which Generate This Code: Troubleshooting: The Electronic Control Module (ECM) detects the following conditions: This diagnostic code detects an abnormal signal from the J1939 data link.

  • Page 87: Cid 0262 Fmi 04

    KENR6201-01 Troubleshooting Section System Response: Results: • The ECM sets all of the pressure sensors and OK – STOP. temperature sensors to the default values. The ECM will log the diagnostic code. If equipped, the i03797692 diagnostic lamp will flash and the derate lamp will CID 0268 FMI 02 come on.

  • Page 88: Cid 0342 Fmi 08

    KENR6201-01 Troubleshooting Section The Electronic Control Module (ECM) detects the i03797713 following conditions: CID 0342 FMI 08 • A low current condition in the output from the ECM to the solenoid for the wastegate regulator Conditions Which Generate This Code: •...

  • Page 89: Cid 1690 Fmi 08

    KENR6201-01 Troubleshooting Section Possible Performance Effect: i03797790 CID 1779 FMI 05 The engine will be derated while this diagnostic code is active. Troubleshooting: Conditions Which Generate This Code: This diagnostic code will detect a fault in the circuit This diagnostic code indicates that the Electronic for the solenoid in the wastegate regulator.

  • Page 90: Cid 1779 Fmi 08

    KENR6201-01 Troubleshooting Section Results: System Response: • OK – STOP. If equipped, the diagnostic lamp will flash and the derate lamp may come on. The ECM will log the diagnostic code. The data for the intake manifold i03799338 pressure will be set to a maximum valid pressure CID 1779 FMI 08 for two seconds.

  • Page 91: Cid 1785 Fmi 10

    KENR6201-01 Troubleshooting Section System Response: The ECM will flag the intake manifold pressure as being invalid. A default value is used for the intake If equipped, the diagnostic lamp will flash and the manifold pressure. derate lamp may come on. The ECM will log the diagnostic code.

  • Page 92: Cid 1797 Fmi 04

    KENR6201-01 Troubleshooting Section Troubleshooting: i03825509 CID 1834 FMI 02 This diagnostic code detects an excessively high voltage from the fuel rail pressure sensor. 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 condition:...
  • Page 93 KENR6201-01 Troubleshooting Section Possible Performance Effect: The ECM is unable to activate the relay for the glow plug starting aid. The glow plugs will not operate or the glow plugs will operate all the time. The engine may be difficult to start in cold temperatures and the exhaust may emit white smoke.

  • Page 94: Troubleshooting With An Event Code

    KENR6201-01 Troubleshooting Section Troubleshooting with an No troubleshooting is required. Event Code Results: • OK – STOP. i02411070 Event Codes i03852049 E255 Diagnostic Reset The Electronic Control Module (ECM) can log events. Events refer to engine operating conditions such as Conditions Which Generate This Code: low oil pressure or high coolant temperature.

  • Page 95: E360 Low Engine Oil Pressure

    KENR6201-01 Troubleshooting Section Possible Performance Effect: E264-1 None Troubleshooting: This event indicates that the emergency stop button has been depressed. This event does not represent a fault in the Electronic Control Module (ECM). The engine will be shut down. No troubleshooting is required. Results: •...

  • Page 96: E361 High Engine Coolant Temperature

    KENR6201-01 Troubleshooting Section System Response: The event code will be logged. The warning lamp will be illuminated and the diagnostic lamp will flash the event code. Possible Performance Effect: E360-1 None E360-3 The derate lamp will be illuminated. The ECM will derate the power at 17 percent per second for two seconds.

  • Page 97: E362 Engine Overspeed

    KENR6201-01 Troubleshooting Section Table 33 Engine Coolant Trip Level Table Engine Model E361-1 E361-2 E361-3 Trip Level 113 °C (233 °F) 114° C (237° F) 118 °C (244 °F) Delay to activation 10 seconds 10 seconds 2 seconds System Response: The event code will be logged.

  • Page 98: E396 High Fuel Rail Pressure

    KENR6201-01 Troubleshooting Section Table 34 Trip Points for Engine Overspeed E362-1 E362-3 Trip Point (RPM) 2200 2300 Delay to Activation 0.6 seconds 0 seconds • Note: The electronic service tool can be used to The ECM detects fuel rail pressure that is more change the trip points for engine overspeed.

  • Page 99: E398 Low Fuel Rail Pressure

    KENR6201-01 Troubleshooting Section The event code does not represent a fault in the i03813929 electronic system. Refer to Systems Operation, E398 Low Fuel Rail Pressure Testing and Adjusting, “Fuel System - Inspect”. Results: Conditions Which Generate This Code: • OK – STOP. The Electronic Control Module (ECM) detects a fault with low fuel rail pressure.
  • Page 100 KENR6201-01 Troubleshooting Section Table 35 Trip Points for the Intake Manifold Air Temperature E539-1 E539-2 Engine Model Turbocharged Aftercooled 82 °C (179 °F) 86 °C (186 °F) Engines (TA) System Response: The warning lamp will be illuminated. If equipped, the diagnostic lamp will flash the event code.

  • Page 101: Diagnostic Functional Tests

    KENR6201-01 Troubleshooting Section Diagnostic Functional Tests i03814010 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: • 262-3 5 Volt Sensor DC Power Supply voltage above normal •...
  • Page 102 KENR6201-01 Troubleshooting Section Table 36 P2 Pin Connections Sensor Pin Function Fuel Rail Pressure Intake Manifold Oil Pressure sensor Sensor Pressure Sensor +5 Volts DC Common Signal g01800518 Illustration 14 Typical example of the schematic for the sensors This document is printed from SPI². Not for RESALE...
  • Page 103 KENR6201-01 Troubleshooting Section g01800553 Illustration 15 Typical example of the locations of the P2 pins for the pressure sensors (38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (+5 Volts DC) Oil (55) Signal (SIG) Intake Manifold Pressure Sensor Pressure Sensor Sensor (39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (+5 Volts DC) Fuel Rail...
  • Page 104 KENR6201-01 Troubleshooting Section Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Verify that the repair eliminates the fault. STOP. Test Step 2. Check for Active Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector.
  • Page 105 Use the electronic service tool in order to Troubleshooting, “Flash Programming”. clear all logged diagnostic codes. Replace all wires to the original configuration. 2. Contact Perkins Global Technical Support. Verify that the repair eliminates the fault. Note: This consultation can greatly reduce the repair time.
  • Page 106 KENR6201-01 Troubleshooting Section 7. Use the electronic service tool in order to clear Verify that the repair eliminates the fault. all logged diagnostic codes and then verify that the repair eliminates the fault. STOP. Test Step 7. Measure the +5 Volt Supply STOP.

  • Page 107: Can Data Link Circuit - Test

    KENR6201-01 Troubleshooting Section • Not OK – The voltage is not within the range. Repair: Inspect the common wire for an open circuit. Repair the common wire and/or replace the common wire. Verify that the repair eliminates the fault. STOP. i03814034 CAN Data Link Circuit - Test System Operation Description:...
  • Page 108 KENR6201-01 Troubleshooting Section g01801898 Illustration 19 Typical example of the schematic for the CAN data link g01801913 Illustration 20 Typical view of the pin locations on the P1connector (20) CAN- (21) CAN+ (22) CAN Shield Test Step 1. Inspect Electrical Connectors C.
  • Page 109 KENR6201-01 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 110: Data Link Circuit - Test

    KENR6201-01 Troubleshooting Section Results: The version of the ECM is not recognized and the integrity of the changed parameters and displayed • OK – The other devices are operating correctly. data is not guaranteed. Repair: Repeat this test procedure from Test Step This message will indicate that the version of the software that is in the electronic service tool is not the same version of the software that is in the ECM.
  • Page 111 KENR6201-01 Troubleshooting Section g01801933 Illustration 21 Schematic of the diagnostic connector and the data link connector g01801995 Illustration 22 Typical view of the P1 pin locations for the diagnostic connector (23) Data link + (24) Data link - This document is printed from SPI². Not for RESALE...
  • Page 112 KENR6201-01 Troubleshooting Section g01801993 Illustration 23 Typical view of the P2 pin locations for the diagnostic connector (20) Data link - (21) Data link + Test Step 1. Inspect Electrical Connectors Repair: Perform the following repair: and Wiring Repair the connectors and/or the harness, or A.
  • Page 113 KENR6201-01 Troubleshooting Section Test Step 4. Check the Battery Voltage at Repair: If this step is being performed as a the Diagnostic Connector result of an instruction in “Check the wiring of the Diagnostic Connector”and if a jumper wire has been installed between pin “A”...
  • Page 114 KENR6201-01 Troubleshooting Section Repair: Perform the following repair: Results: • Repair the connectors and/or the harness, or Result 1 – Proceed to Test Step 7. replace the connectors and/or the harness. Ensure • that all of the seals are correctly in place and Result 2 ensure that the connectors are completely coupled.
  • Page 115 KENR6201-01 Troubleshooting Section g01831237 Illustration 25 Schematic of the bypass harness connector This document is printed from SPI². Not for RESALE...

  • Page 116: Ecm Memory - Test

    (8) Battery + (20) J1939 (CAN) - A. Connect the battery wires from the bypass 4. If Perkins Global Technical Support harness of the electronic service tool to a different recommends the use of a test ECM, install a battery that is not on the engine.

  • Page 117: Electrical Connectors - Inspect

    KENR6201-01 Troubleshooting Section • Always use a 2900A033 Crimp Tool to service 253-2 AMP seal connectors. The flash file in the Electronic Control Module (ECM) • is from the wrong engine family. The engine will not Refer to Troubleshooting, “ECM Harness start.
  • Page 118 KENR6201-01 Troubleshooting Section g01131276 g01131165 Illustration 28 Illustration 30 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 119 KENR6201-01 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 120 KENR6201-01 Troubleshooting Section Test Step 4. Perform a Pull Test on Each Test Step 5. Check Individual Pin Wire Terminal Connection Retention into the Socket g01802454 g01802455 Illustration 31 Illustration 32 A typical example of the lock wedge. Diagram for testing pin retention (1) Lock wedge A.

  • Page 121: Engine Pressure Sensor Open Or Short Circuit - Test

    KENR6201-01 Troubleshooting Section Test Step 8. Perform the “Wiggle Test” Results: on the Electronic Service Tool • OK – The connectors are in good repair. Proceed to Test Step 7. A. Select the “Wiggle Test” from the diagnostic tests on the electronic service tool. •...
  • Page 122 KENR6201-01 Troubleshooting Section • 100-10 Engine Oil Pressure Sensor abnormal rate of change • 1785-3 Intake Manifold Pressure Sensor voltage above normal • 1785-4 Intake Manifold Pressure Sensor voltage below normal • 1785-10 Intake Manifold Pressure Sensor abnormal rate of change •...
  • Page 123 KENR6201-01 Troubleshooting Section g01800518 Illustration 33 Typical example of the schematic for the sensors g01802515 Illustration 34 Typical view of the P2 pressure sensor pin locations (38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (+5 Volts DC) Oil (56) Signal (SIG) Oil Pressure Sensor Sensor Pressure Sensor (39) Ground (GND) Oil Pressure Sensor...
  • Page 124 KENR6201-01 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 DC to terminal 1 of each sensor.
  • Page 125 KENR6201-01 Troubleshooting Section If the preceding codes are logged, an intermittent Use the electronic service tool in order to clear all condition may be causing the logged codes. logged diagnostic codes and then verify that the Refer to Troubleshooting, “Electrical Connectors repair eliminates the fault.
  • Page 126 KENR6201-01 Troubleshooting Section Expected Result: D. If the short circuit diagnostic code reappears, the sensor or the sensor connector has a fault. A “Voltage Below Normal” diagnostic code for the disconnected sensor is now active. a. Temporarily connect a new sensor to the harness, but do not install the new sensor in Results: the engine.
  • Page 127 ECM by Creating Open and Short Circuits Troubleshooting, “Flash Programming”. at the ECM Connector 2. Contact Perkins Global Technical Support. A. Turn the keyswitch to the OFF position. Note: This consultation can greatly reduce the repair B. Disconnect connector P2 from the ECM.

  • Page 128: Engine Speed/Timing Sensor Circuit - Test

    KENR6201-01 Troubleshooting Section E. Fabricate a jumper wire that is long enough to i03816249 reach from the ECM to the sensor connector or Engine Speed/Timing Sensor use an engine sensor harness bypass with 3 Circuit - Test terminals. Note: If an engine sensor harness bypass is being made, crimp a socket on one end in order to connect to the ECM.
  • Page 129 KENR6201-01 Troubleshooting Section The loss of signal to the primary sensor and/or the secondary sensor will result in one of the following faults: • The loss of signal from the secondary speed/timing sensor during start-up will prevent the engine from starting.
  • Page 130 KENR6201-01 Troubleshooting Section g01188474 Illustration 39 Typical view of the pin locations for the speed/timing sensors (10) Speed/ Timing sensor supply (8v) (52) Primary speed/timing sensor signal (53) Secondary speed/timing sensor signal g01188476 Illustration 40 Typical view of the sensor locations (1) Primary speed/timing sensor (2) Secondary speed/timing sensor This document is printed from SPI².
  • Page 131 KENR6201-01 Troubleshooting Section g01188477 Illustration 41 (1) Primary speed/timing sensor (crankshaft) g01212569 Illustration 42 (2) Secondary speed/timing sensor (camshaft) Test Step 1. Inspect the Electrical Connectors and the Harness g01212995 Illustration 43 Typical example of a speed/timing sensor (1) Voltage Supply (8V) (2) Signal A.
  • Page 132 KENR6201-01 Troubleshooting Section E. Check the harness for abrasion and pinch points Expected Result: from the suspect sensor to the ECM. One or more of the following diagnostic codes are F. Check that the suspect sensor is installed active or recently logged: correctly.
  • Page 133 KENR6201-01 Troubleshooting Section Test Step 4. Check the Harness Between D. Measure the resistance from P2:10 speed/timing the Primary Speed/Timing Sensor and sensor (+8 V supply) to all other pins on the P2. the ECM Measure the resistance from P2:10 speed/timing sensor (+8 V supply) to the ground and the battery+ terminals.
  • Page 134 B. Disconnect the suspect sensor and remove the suspect sensor from the engine. C. If Perkins Global Technical Support recommends the use of a test ECM, install a test ECM. Refer to C. If a sensor must be replaced or a sensor must be Troubleshooting, “Replacing the ECM”.

  • Page 135: Engine Temperature Sensor Open Or Short Circuit - Test

    KENR6201-01 Troubleshooting Section i03816070 Engine Temperature Sensor Open or Short Circuit - Test System Operation Description: Use this procedure under the following conditions: This procedure covers open circuit diagnostic codes and short circuit diagnostic codes that are associated with the following sensors: •...
  • Page 136 KENR6201-01 Troubleshooting Section g01803534 Illustration 44 Schematic for engine temperature sensors g01803535 Illustration 45 Typical view of the P2 pin locations for the pressure sensor (37) Ground (GND) Intake Manifold Air (42) Signal (SIG) Intake Manifold Air Temperature Sensor Temperature Sensor (37) Ground (GND) Coolant Temperature (43) Signal (SIG) Coolant Temperature Sensor...
  • Page 137 KENR6201-01 Troubleshooting Section Test Step 2. Inspect Electrical Connectors And Wiring A. Thoroughly inspect ECM engine harness connector P2 and the suspect sensor connector. Refer to Troubleshooting, “Electrical Connectors - Inspect”. B. Perform a 45 N (10 lb) pull test on each of the wires in the sensor connector and the ECM connector that are associated with the active diagnostic code.
  • Page 138 KENR6201-01 Troubleshooting Section Expected Result: 4. Use the electronic service tool to remove all inactive diagnostic fault codes. A short circuit diagnostic code or an open circuit diagnostic code is active. STOP. • Results: Not OK – There is a short circuit between the sensor harness connector and the ECM.
  • Page 139 Troubleshooting, “Flash Programming”. for signs of corrosion or moisture. Refer to Troubleshooting, “Electrical Connectors - Inspect”. 2. Contact Perkins Global Technical Support. D. Turn the keyswitch to the ON position. Use the Note: This consultation can greatly reduce the repair electronic service tool in order to monitor the time.

  • Page 140: Fuel Rail Pump Solenoid - Test

    KENR6201-01 Troubleshooting Section F. Insert one end of the jumper into the ECM Note: The fuel rail pump is installed on the engine at connector. Insert the other end of the jumper into the factory. The fuel rail pump is not a serviceable the sensor connector of the engine harness.
  • Page 141 KENR6201-01 Troubleshooting Section g01803553 Illustration 47 Typical schematic of the circuit for the fuel rail pump solenoid g01803554 Illustration 48 Typical view of the pin locations on theP2 connector for the fuel rail pump solenoid (25) Fuel rail pump solenoid PWM signal (26) Fuel rail pump solenoid return Test Step 1.
  • Page 142 KENR6201-01 Troubleshooting Section • Not OK – There is a fault with the connectors B. Disconnect P2 from the ECM. and/or the harness. C. Measure the resistance between P2:25 and P2:26. Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Expected Result: Ensure that all of the seals are correctly in place and ensure that the connectors are completely...
  • Page 143 KENR6201-01 Troubleshooting Section Verify that the repair eliminated the fault. Verify that the repair eliminates the fault. STOP. If the diagnostic code has been cleared, then install the new fuel rail pump to the engine. Refer to • Not OK – The fuel rail pump solenoid is faulty. Disassembly and Assembly, “Fuel injection Pump - Remove”...

  • Page 144: Ignition Keyswitch Circuit And Battery Supply Circuit - Test

    Unswitched battery+ C. If Perkins Global Technical Support recommends voltage is supplied through P1: 7, 8, 15 and 16. The the use of a test ECM, install a test ECM. Refer to battery- is supplied through P1: 1, 2, 3, 9 and 10.
  • Page 145 KENR6201-01 Troubleshooting Section Some applications may be equipped with an engine protection shutdown system or an idle timer shutdown system that interrupts electrical power to the keyswitch. The engine protection shutdown system can be an aftermarket device and the idle timer shutdown system can be external to the ECM.
  • Page 146 KENR6201-01 Troubleshooting Section g01803755 Illustration 49 Schematic for the ignition keyswitch and battery supply circuit g01803934 Illustration 50 View of the pin locations on the P1 connector for the ignition keyswitch and battery supply circuit (1) Battery ground (GND) (8) Battery+ (16) Battery+ (2) Battery ground (GND) (9) Battery ground (GND)
  • Page 147 KENR6201-01 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 148 KENR6201-01 Troubleshooting Section F. Measure the voltage between P1:16 (keyswitch) Expected Result: and P1:10 (Battery-). The batteries pass the load test. For 12 Volt systems, G. Measure the voltage between P1:40 (keyswitch) the measured voltage is at least 11.0 Volts DC. For and P1:3 (Battery-).
  • Page 149 ECM. Refer to Troubleshooting, “Flash Programming”. Note: Remove the bypass harness and restore all wiring to the original condition after testing. 3. Contact Perkins Global Technical Support. Expected Result: Note: This consultation can greatly reduce the repair time.

  • Page 150: Indicator Lamp Circuit - Test

    KENR6201-01 Troubleshooting Section 4. If Perkins Global Technical Support recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, “Replacing the ECM”. 5. Use the electronic service tool to recheck the system for active diagnostic codes.
  • Page 151 KENR6201-01 Troubleshooting Section g02053753 Illustration 52 Typical schematic of the circuit for the indicator lamps This document is printed from SPI². Not for RESALE...
  • Page 152 KENR6201-01 Troubleshooting Section g02053754 Illustration 53 Pin locations for the indicator lamps on the P1 connector (1) Ground (GND) (8) Battery (+) (59) Derate lamp (2) Ground (GND) (15) Battery (+) (60) Warning lamp (3) Ground (GND) (16) Battery (+) (61) Low oil pressure lamp (9) Ground (GND) (17) Maintenance lamp...
  • Page 153 ECM. Refer to Troubleshooting, “Flash Programming”. Expected Result: 2. Contact Perkins Global Technical Support. When the jumper is connected, the diagnostic lamp Note: This consultation can greatly reduce the repair comes on. Also, the diagnostic lamp goes off when time.

  • Page 154: Injector Data Incorrect - Test

    KENR6201-01 Troubleshooting Section • 3. If Perkins Global Technical Support 253-2 Personality Module mismatch recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, “Replacing Refer to Troubleshooting, “Injector Trim File” for the ECM”. further information.
  • Page 155 OK – Result 1 One or more diagnostic codes are time. logged. Proceed to Test Step 2. C. If the Perkins Global Technical Support • recommends the use of a test ECM, install a test OK – Result 2 Three injectors that share a common supply indicate a diagnostic code.

  • Page 156: Injector Solenoid Circuit - Test

    KENR6201-01 Troubleshooting Section Repair: Repeat the test procedure from Test Step If an open is detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire the injector. If a short is detected, a STOP.
  • Page 157 KENR6201-01 Troubleshooting Section g01810354 Illustration 56 Schematic of the circuit for the injector solenoids g01237524 Illustration 57 Typical example of a harness connector for a fuel injector g01237558 Illustration 58 Typical example of the cylinder head connector This document is printed from SPI². Not for RESALE...
  • Page 158 KENR6201-01 Troubleshooting Section g01805334 Illustration 59 View of the pin locations on the P2connector for the injectors (6) Injector (Number 6 Return) (34) Injector (Number 2 Return) (59) Injector (Number 3) (7) Injector (Number 5 Return) (35) Injector (Number 1 Return) (62) Injector (Number 6) (8) Injector (Number 4 Return) (57) Injector (Number 1)
  • Page 159 KENR6201-01 Troubleshooting Section • 1-5 Cylinder #1 Injector open circuit Note: The “Manual Cylinder Cutout Test” is also available. Access the manual test by selecting the • 1-6 Cylinder #1 Injector short “Change” button on the screen for the cylinder cutout test.
  • Page 160 KENR6201-01 Troubleshooting Section Note: Do not confuse the “Injector Solenoid Test” F. Perform the “Injector Solenoid Test” at least two with the “Cylinder Cutout Test”. The “Cylinder Cutout times. Test” is used to shut off fuel to a specific cylinder while the engine is running.
  • Page 161 ECM. Refer to Test Step 7. Check the ECM for an Open Troubleshooting, “Flash Programming”. Circuit 3. Contact Perkins Global Technical Support. Note: This consultation can greatly reduce the repair time. Electrical shock hazard. The electronic unit injec- tor system uses 67-73 volts.
  • Page 162 • OK – All cylinders indicate “Open”. Proceed to Troubleshooting, “Flash Programming”. Test Step 10. 2. Contact Perkins Global Technical Support. • Not OK – One or more cylinders indicate “Short”. Note the cylinders that indicate “Short”. Proceed Note: This consultation can greatly reduce the repair to Test Step 9.

  • Page 163: Speed Control (Analog) - Test

    KENR6201-01 Troubleshooting Section E. Perform the “Injector Solenoid Test” at least two Replace the faulty injector. times. Perform the “Injector Solenoid Test”. Expected Result: Verify that the repair eliminates the fault. All of the injectors that were disconnected indicate “Open”. STOP.
  • Page 164 KENR6201-01 Troubleshooting Section g01810415 Illustration 60 Schematic of the analog speed control device g01810453 Illustration 61 Typical view of the pin locations on the P1connector for the speed control circuit (33) Device ground (GND) (54) Analog throttle input 1 Test Step 1. Check for Connector Damage Expected Result: A.
  • Page 165 ECM. Refer to system is correct. Troubleshooting, “Flash Programming”. Expected Result: 2. Contact Perkins Global Technical Support. Note: This consultation can greatly reduce the repair The output signal from the control system should be time.

  • Page 166: Speed Control (Pwm) - Test

    KENR6201-01 Troubleshooting Section i03813871 Speed Control (PWM) - Test System Operation Description: Use this procedure under the following conditions: Use this procedure if the following diagnostic code is indicated: • 91-8 Throttle Position Signal Abnormal Also, use this procedure if the digital speed control device is suspected of incorrect operation.
  • Page 167 KENR6201-01 Troubleshooting Section g01810793 Illustration 63 Typical example of the pin locations on the P1 connector (33) Digital speed demand device return (53) Digital speed demand device input Test Step 1. Inspect Electrical Connectors Repair the connectors or the harness and/or and Wiring replace the connectors or the harness.

  • Page 168: Starting Aid (Glow Plug) Relay Circuit - Test

    ECM. Refer to Troubleshooting, “Flash Programming”. B. Check that the output signal from the control system is correct. 2. Contact Perkins Global Technical Support. Expected Result: Note: This consultation can greatly reduce the repair time.
  • Page 169 KENR6201-01 Troubleshooting Section The starting aid is used to improve the engine starting when the engine is cold. With the keyswitch in the ON position, the engine Electronic Control Module (ECM) will monitor the coolant temperature and the engine intake manifold air temperature in order to decide if the glow plugs are required to be switched ON.
  • Page 170 KENR6201-01 Troubleshooting Section g02053833 Illustration 65 Typical view of the pin locations on the P1 connector for the starting aid (1) Ground (GND) (3) Ground (GND) (10) Ground (GND) (2) Ground (GND) (9) Ground (GND) (57) Start aid control Test Step 1. Inspect Electrical Connectors •...
  • Page 171 Locate the short circuit in the harness. Repair the connectors or the harness and/or replace the B. Contact Perkins Global Technical Support. connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the Note: This consultation can greatly reduce the repair connectors are correctly coupled.

  • Page 172: Wastegate Solenoid - Test

    KENR6201-01 Troubleshooting Section C. If Perkins Global Technical Support recommends The control system for the electronically controlled the use of a test ECM, install a test ECM. Refer to wastegate precisely regulates the intake manifold Troubleshooting, “Replacing the ECM”. pressure by using a wastegate regulator to control the wastegate.
  • Page 173 KENR6201-01 Troubleshooting Section Table 38 Pin Connections Sensor Pin Function P2 Pin Connection Ground Signal g01806857 Illustration 66 Schematic for the wastegate regulator g01806859 Illustration 67 Typical view of the pin locations on the P1 connector for the wastegate regulator (17) Wastegate pulse width modulation (PWM) signal (44) Wastegate return...
  • Page 174 KENR6201-01 Troubleshooting Section Repair: For intermittent faults, refer to Troubleshooting, “Electrical Connectors - Inspect”. STOP. Test Step 2. Inspect Electrical Connectors and Wiring A. Thoroughly inspect the P2/J2 connectors and the P511 connector for the wastegate regulator. Refer to Troubleshooting, “Electrical Connectors - Inspect”...
  • Page 175 ECM. Refer to Repair: Perform the following procedure: Troubleshooting, “Flash Programming”. 1. Temporarily connect a replacement wastegate 2. Contact Perkins Global Technical Support. regulator. Note: This consultation can greatly reduce the repair 2. Turn the keyswitch to the ON position. Access time.
  • Page 176 1. Make sure that the latest flash file for the Expected Result: application is installed in the ECM. Refer to Troubleshooting, “Flash Programming”. The 526-5 diagnostic code is now active. 2. Contact Perkins Global Technical Support. Results: Note: This consultation can greatly reduce the repair • time.

  • Page 177: Index

    KENR6201-01 Index Section Index CID 0168 FMI 00 ........... 83 Numerics CID 0168 FMI 01 ........... 83 CID 0168 FMI 02 ........... 84 5 Volt Sensor Supply Circuit - Test ...... 101 CID 0172 FMI 03 ........... 84 CID 0172 FMI 04 ........... 85 CID 0190 FMI 08 ...........
  • Page 178 Probable Causes ..........43 Recommended Actions........43 Electronic Service Tools ......... 11 Optional Service Tools ........11 Perkins Electronic Service Tool......11 Required Service Tools ........11 Ignition Keyswitch Circuit and Battery Supply Circuit - Electronic Troubleshooting ........5 Test ..............144 Engine Cranks but Will Not Start ......
  • Page 179 KENR6201-01 Index Section Noise Coming from Cylinder........67 Probable Causes ..........67 Recommended Actions........67 Programming Parameters ........26 Replacing the ECM..........16 Self-Diagnostics............. 17 Sensors and Electrical Connectors ....... 17 Speed Control (Analog) - Test ......163 Speed Control (PWM) - Test........ 166 Speed Demand Input Setup ........
  • Page 180 ©2010 Perkins Engines Company Limited Printed in U.K. All Rights Reserved This document is printed from SPI². Not for RESALE...

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