Page 1 UENR0612-06 February 2015 Troubleshooting 854F-E34T and 854E-E34TA Industrial Engines JR (Engine) JS (Engine) JT (Engine) This document has been 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
UENR0612 Table of Contents Table of Contents Engine Stalls at Low RPM ......72 Engine Top Speed Is Not Obtained ....74 Engine Vibration Is Excessive ......77 Troubleshooting Section Exhaust Has Excessive Black Smoke.... 79 Exhaust Has Excessive White Smoke ....
Page 4 UENR0612 Table of Contents Water in Fuel - Test........234 Service Service Tool Features........238 Electronic Service Tool Does Not Communicate..........239 ECM Software - Install ........241 ECM - Replace ..........242 Electrical Connectors - Inspect..... 243 Injector Code - Calibrate....
Page 5: Troubleshooting Section
ARD. The software controls the delivery of warnings are not heeded, bodily injury or death could fuel, combustion air, and the spark to the ARD. occur to you or to other persons. Perkins cannot anticipate every possible circumstance that might involve a potential hazard.
Page 6: Welding Precaution
4. Disconnect all electronic components from the Electronic Service Tools wiring harnesses. Include the following components: Perkins electronic service tools are designed to help • Electronic components for the driven equipment the service technician: • ECM • Retrieve diagnostic codes •...
Page 7 Suitable Digital Pressure Indicator 27610401 Perkins CA3 Kit Engine Pressure Group Refer to Perkins Engine Company Limited. Suitable Battery Load Tester Note: For more information on the Electronic Service Tool and the PC requirements, refer to the Suitable Temperature Adapter...
Page 8 UENR0612 Introduction Connecting the Electronic Service Tool Connecting the Electronic Service Tool and the TIPSS Adapter and the CA3 Kit Illustration 2 g01121866 Illustration 3 g01121866 (1) Personal Computer (PC) (1) Personal Computer (PC) (2) Adapter Cable (Computer Serial Port) (2) Adapter Cable (Computer Serial Port) (3) TIPSS adapter (3) CA3 adapter...
Page 9: Electronic System Overview
UENR0612 Electronic System Overview Electronic System Fuel Injection Overview The ECM sends a high voltage signal to the injector solenoids in order to energize the solenoids. By controlling the timing and the duration of the high voltage signal, the ECM can control the following aspects of injection: i05980308 •...
Page 10: Component Location
UENR0612 Electronic System Overview i06043596 Component Location Electronic Control Circuit Diagram Illustration 4 g03746141 Electronic control circuit diagram for the 854E-E34TA (model JR) engine This document has been printed from SPI2. NOT FOR RESALE...
Page 11 UENR0612 Electronic System Overview Illustration 5 g03746149 Electronic control circuit diagram for the 854F-E34T (model JS) engine This document has been printed from SPI2. NOT FOR RESALE...
Page 12 UENR0612 Electronic System Overview Illustration 6 g03746150 Electronic control circuit diagram for the 854F-E34T (model JT) engine This document has been printed from SPI2. NOT FOR RESALE...
Page 13 UENR0612 Electronic System Overview C3.4B Engine Illustration 7 g02737916 Sensors and electrical connector locations on the left side of the engine (typical example) (1) 10-pin engine interface connector (3) Fuel rail pressure sensor (6) Oil pressure switch (optional) (4) Fuel temperature sensor (7) Primary speed/timing sensor (crankshaft) (2) 62-pin engine interface connector (5) High-pressure fuel pump inlet metering...
Page 14 UENR0612 Electronic System Overview Illustration 8 g02737996 Close up views of the sensor locations on the left side of the engine (typical example) (1) 10-pin engine interface connector (3) Fuel rail pressure sensor (6) Oil pressure switch (optional) (4) Fuel temperature sensor (7) Primary speed/timing sensor (crankshaft) (2) 62-pin engine interface connector (5) High-pressure fuel pump inlet metering...
Page 15 UENR0612 Electronic System Overview Illustration 9 g02737956 Sensors and electrical connector locations on the right side of the 854E-E34TA (model JR) engine (typical example) (9) Intake manifold air pressure and (11) Exhaust gas pressure sensor (14) Oxygen sensor temperature sensor (12) NOx Reduction System (NRS) valve (10) Exhaust temperature sensor connector (13) Wastegate regulator...
Page 16 UENR0612 Electronic System Overview Illustration 10 g03356014 Sensors and electrical connector locations on the right side of the 854F-E34T (model JS) engine and 854F-E34T (model JT) engine (15) Intake manifold temperature sensor (17) Exhaust gas pressure sensor (19) Wastegate regulator...
Page 17 UENR0612 Electronic System Overview Illustration 11 g03356021 Sensors and electrical connection locations on the front of the engine. (21) Intake throttle valve (23) Secondary (camshaft) speed/timing (22) Coolant temperature sensor sensor This document has been printed from SPI2. NOT FOR RESALE...
Page 18 Clean Emissions Module (CEM) Illustration 12 g03356022 Typical view of the sensor locations on the CEM on the 854E-E34TA (model JR) engine and 854F-E34T (model JS) engine (24) Diesel Oxidation Catalyst (DOC) inlet (26) Inlet connection for the DPF differential...
Page 19: Diesel Particulate Filter Regeneration
UENR0612 Electronic System Overview • Viewing parameters i05980520 Diesel Particulate Filter • Parameter programming Regeneration • Set delay times The default settings for the parameters are programmed at the factory. To accommodate unique Regeneration applications and sites, some of the parameters may be reprogrammed with the electronic service tool.
Page 20: Electrical Connectors
UENR0612 Electronic System Overview i05981997 Electrical Connectors Connectors for the Electronic Control Module (ECM) Illustration 14 g03747067 View of the engine ECM (1) J1 ECM connector (2) J2 ECM connector This document has been printed from SPI2. NOT FOR RESALE...
Page 21 UENR0612 Electronic System Overview Illustration 15 g02277053 View of the J1 ECM connector (ECM side) Illustration 16 g02266273 View of the J2 ECM connector (ECM side) This document has been printed from SPI2. NOT FOR RESALE...
Page 22: Configuration Parameters
UENR0612 Configuration Parameters Configuration Parameters i05982913 Configuration Parameters The electronic service tool can be used to view certain parameters that can affect the operation of the engine. The electronic service tool can also be used to change certain parameters. Some parameters cannot be changed and some applications do not allow any changes to the programmable monitoring system.
Page 23: Diagnostic Trouble Codes
UENR0612 Diagnostic Trouble Codes Diagnostic Trouble Codes i05991929 Diagnostic Trouble Codes The following table lists all the J1939 diagnostic trouble codes for the engine. The table includes a description for each code and the recommended troubleshooting procedure that must be performed. Table 4 Description J1939 Code...
Page 24 UENR0612 Diagnostic Trouble Codes (Table 4, contd) Description J1939 Code Refer to Procedure Engine Coolant Temperature : High - moderate severity (2) Coolant Temperature Is High 110-16 Number Of ECU Resets : Erratic, Intermittent, or Incorrect ECM Memory - Test 152-2 Engine Injector Metering Rail #1 Pressure : High - most severe 157-0...
Page 25 UENR0612 Diagnostic Trouble Codes (Table 4, contd) Description J1939 Code Refer to Procedure Calibration Memory : Erratic, Intermittent, or Incorrect Injector Data Incorrect - Test 630-2 Engine Timing Sensor : Other Failure Mode Speed/Timing - Test 637-11 J1939 Network #1 : Abnormal Update Rate 639-9 Data Link - Test J1939 Network #1 : Special Instruction...
Page 26 UENR0612 Diagnostic Trouble Codes (Table 4, contd) Description J1939 Code Refer to Procedure Engine Wait to Start Lamp : Current Below Normal Indicator Lamp - Test 1081-5 Engine Wait to Start Lamp : Current Above Normal Indicator Lamp - Test 1081-6 The engine protection system has shutdown the engine.
Page 27 UENR0612 Diagnostic Trouble Codes (Table 4, contd) Description J1939 Code Refer to Procedure Accelerator Pedal 2 Low Idle Switch : Erratic, Intermittent, or 2970-2 Idle Validation - Test Incorrect Aftertreatment #1 Intake O2 : Voltage Above Normal Oxygen Level - Test 3217-3 Aftertreatment #1 Intake O2 : Voltage Below Normal Oxygen Level - Test...
Page 28 UENR0612 Diagnostic Trouble Codes (Table 4, contd) Description J1939 Code Refer to Procedure Particulate Trap Lamp Command : Current Above Normal Indicator Lamp - Test 3697-6 Exhaust System High Temperature Lamp Command : Current Indicator Lamp - Test 3698-5 Below Normal Exhaust System High Temperature Lamp Command : Current Indicator Lamp - Test 3698-6...
Page 29 UENR0612 Diagnostic Trouble Codes (Table 4, contd) Description J1939 Code Refer to Procedure High Pressure Common Rail Fuel Pressure Relief Valve : High - 5571-16 Fuel Rail Pressure Problem moderate severity (2) Emission Control System Operator Inducement Severity : High - See “Operator Inducement Codes”.
Page 30 UENR0612 Diagnostic Trouble Codes (Table 5, contd) Description J1939 Code Refer to Procedure Engine Fuel Injection Pump Fuel Control Valve : Current Above 1076-6 Solenoid Valve - Test Normal Engine Turbocharger Wastegate Actuator 1 Position : Current 1188-5 Solenoid Valve - Test Below Normal Engine Exhaust Gas Pressure : Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test...
Page 31: Symptom Troubleshooting
UENR0612 Symptom Troubleshooting Symptom Troubleshooting i05982962 Acceleration Is Poor or Throttle Response Is Poor Probable Causes • Diagnostic codes • Parameters in the Electronic Control Module (ECM) • Throttle Position Sensor/Throttle Switches • Air intake and exhaust system • Valve lash •...
Page 32 UENR0612 Symptom Troubleshooting Table 6 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Engine Derate Result: A diagnostic code is present. or Diagnostic Note: Certain diagnostic codes may cause poor performance. Codes Troubleshoot the diagnostic code. Refer to Troubleshoot- ing, “Diagnostic Trouble Codes”. A.
Page 33 UENR0612 Symptom Troubleshooting (Table 6, contd) Troubleshooting Test Steps Values Results 7. Turbocharger Turbocharger Result: There is a fault on the turbocharger. Note: The turbocharger that is installed on the engine is a nonser- Repair the turbocharger or replace the turbocharger. Refer viceable item.
Page 34: Alternator Problem (Charging Problem And/Or Noisy Operation)
UENR0612 Symptom Troubleshooting (Table 6, contd) Troubleshooting Test Steps Values Results 9. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the compression specifications. A. Perform a compression test. Refer to Systems Operation, Test- ing, and Adjusting, “Compression - Test”. Investigate the cause and rectify any faults.
Page 35 UENR0612 Symptom Troubleshooting Table 7 Troubleshooting Test Steps Values Results 1. Condition of the Alternator Drive Belts Drive belt Result: The alternator drive belts are in good condition and the belt tension is correct. A. Inspect the condition of the alternator drive belts. Proceed to Test Step 2.
Page 36: Battery Problem
UENR0612 Symptom Troubleshooting i05989429 Battery Problem Probable Causes • Charging circuit • Battery • Auxiliary device Recommended Actions Complete the procedure in the order in which the steps are listed. Table 8 Troubleshooting Test Steps Values Results 1. Charging Circuit Charging Result: The charging circuit is not OK.
Page 37: Coolant Contains Oil
UENR0612 Symptom Troubleshooting i05952261 Coolant Contains Oil Probable Causes • Engine oil cooler • Cylinder head gasket • Cylinder head • Cylinder block Recommended Actions Complete the procedure in the order in which the steps are listed. Table 9 Troubleshooting Test Steps Values Results 1.
Page 38: Coolant Level Is Low
UENR0612 Symptom Troubleshooting (Table 9, contd) Troubleshooting Test Steps Values Results 3. Cylinder Head Cylinder head Result: A fault is found in the cylinder head. A. Check for cracks in the cylinder head. Perform a leak test on Repair the cylinder head or replace the cylinder head. In- the cylinder head.
Page 39 UENR0612 Symptom Troubleshooting Table 10 Diagnostic Trouble Codes for High Coolant Temperature Description J1939 Code Notes 110-15 Engine Coolant Temperature : High - least The Electronic Control Module (ECM) detects that the coolant temperature severe (1) is greater than 110° C (230° F) for at least 0.5 seconds. The code will be reset if the coolant temperature is less than 110°...
Page 40 UENR0612 Symptom Troubleshooting Table 11 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: Diagnostic codes are not present. Codes A. Use the electronic service tool to check for diagnostic codes that Return the unit to service. relate to the temperature in the cooling system. Result: Diagnostic codes are present.
Page 41 UENR0612 Symptom Troubleshooting (Table 11, contd) Troubleshooting Test Steps Values Results 6. Water Temperature Regulator Water Temper- Result: The water temperature regulator is not operating ature Regulator correctly. A. Check the water temperature regulator for correct operation. Re- fer to Systems Operation, Testing, and Adjusting, “Cooling System” Replace the water temperature regulator.
Page 42: Crankcase Breather Ejects Oil
UENR0612 Symptom Troubleshooting (Table 11, contd) Troubleshooting Test Steps Values Results 9. Inspection of the Coolant Pump Coolant pump Result The coolant pump is damaged or not operating correctly. A. Inspect the impeller of the coolant pump for damage and/or erosion.
Page 43 UENR0612 Symptom Troubleshooting Probable Causes Recommended Actions • Breather filter • Breather hoses • Breather heater • Excessive blow-by Illustration 18 g02919737 This document has been printed from SPI2. NOT FOR RESALE...
Page 44 UENR0612 Symptom Troubleshooting Table 12 Troubleshooting Test Steps Values Results 1. Breather Filter Breather filter Result: The breather element is incorrectly installed or damaged. A. Check that the breather element is correctly installed and that the element is not damaged. Install a new filter element.
Page 45: Cylinder Is Noisy
UENR0612 Symptom Troubleshooting i05991971 Cylinder Is Noisy Probable Causes • Diagnostic codes • Fuel quality • Valve train components • Injectors • Pistons Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 13 Troubleshooting Test Steps Values...
Page 46: Diesel Particulate Filter Active Regeneration Occurrence Is Excessive
UENR0612 Symptom Troubleshooting (Table 13, contd) Troubleshooting Test Steps Values Results 3. Valve Train Components Valve train Result: Valve train components are damaged. A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Make the necessary repairs, Verify that the repair has elimi- Excessive”.
Page 47 UENR0612 Symptom Troubleshooting Table 14 Troubleshooting Test Steps Values Results 1. Insulation on the Exhaust Duct (if equipped) Codes Result: The insulation is missing or damaged. A. Check the insulation on the exhaust duct between the engine Repair or replace the insulation. and the Clean Emissions Module (CEM).
Page 48: Diesel Particulate Filter Active Regeneration Was Interrupted
UENR0612 Symptom Troubleshooting (Table 14, contd) Troubleshooting Test Steps Values Results 4. Low Compression (Cylinder Pressure) Low compression Result: Low compression is recorded on one or more cylinders. A. Perform a compression test. Refer to Systems Operation, Test- ing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the fol- lowing list: ·...
Page 49: Diesel Particulate Filter Collects Excessive Soot
UENR0612 Symptom Troubleshooting Table 16 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Codes Result: A diagnostic trouble code is active or logged. A. Establish communication between the electronic service tool and Troubleshoot any diagnostic codes that could have caused the Electronic Control Module (ECM).
Page 50 UENR0612 Symptom Troubleshooting (Table 17, contd) 3251-16 Particulate Trap Differential Pressure : High - moderate se- The Electronic Control Module (ECM) detects the following verity (2) conditions: The differential pressure across the DPF is high for at least 100 seconds. The pressure at which this code becomes active is dependent on the level of soot indicated by the soot model that is calculated by the ECM.
Page 51: Diesel Particulate Filter Has Differential Pressure Problem
UENR0612 Symptom Troubleshooting Table 18 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: A diagnostic trouble code is active or logged. codes A. Establish communication between the electronic service tool and Troubleshoot any related diagnostic codes before continu- the Electronic Control Module (ECM).
Page 52 UENR0612 Symptom Troubleshooting Table 19 Diagnostic Trouble Codes for the DPF Differential Pressure Description J1939 Code Notes 3251-7 Particulate Trap Differential Pressure : Not Responding Properly The Electronic Control Module (ECM) detects the following conditions: The measured differential pressure from the DPF differential pressure sensor is invalid.
Page 53 UENR0612 Symptom Troubleshooting Table 20 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: A 3251-3 or 3251-4 diagnostic code is active codes A. Establish communication between -the electronic service tool Refer to Troubleshooting, “Sensor Signal (Analog, Active) - and the Electronic Control Module (ECM).
Page 54: Diesel Particulate Filter Temperature Is Low
UENR0612 Symptom Troubleshooting Table 21 Troubleshooting Test Steps Values Results 3. Connections to the DPF Differential Pressure Sensor Damage and/ Result: One of the connections is damaged and/or blocked or blockages A. Thoroughly inspect the following components for blockages and/ Replace any damaged or blocked components.
Page 55: Engine Cranks But Does Not Start
UENR0612 Symptom Troubleshooting Table 22 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Codes Result: A diagnostic trouble code is active or logged. A. Establish communication between the electronic service tool and Troubleshoot any diagnostic codes before continuing with the Electronic Control Module (ECM). this procedure.
Page 56 UENR0612 Symptom Troubleshooting Table 23 Troubleshooting Test Steps Values Results 1. Ground Level Shutdown Switch (If Equipped) Shutdown switch Result: The ground level shutdown switch has been activated. A. Ensure that the ground level shutdown switch has not been activated. Deactivate the ground level shutdown switch.
Page 57 UENR0612 Symptom Troubleshooting (Table 23, contd) Troubleshooting Test Steps Values Results 4. Air Intake and Exhaust System Defects Result: A defect was found in the air intake or exhaust system. A. Check the air filter restriction indicator. Make any necessary repairs. B.
Page 58 UENR0612 Symptom Troubleshooting Illustration 20 g03705140 View of the fuel manifold (typical example) This document has been printed from SPI2. NOT FOR RESALE...
Page 59 UENR0612 Symptom Troubleshooting Table 24 Troubleshooting Test Steps Values Results 7. Fuel Rail Pressure Relief Valve (PRV) Fuel in container Result: Fuel is present in the container. A. Turn the keyswitch to the OFF position. Install a replacement fuel manifold. Refer to Disassembly and Assembly, “Fuel Manifold (Rail) - Remove and Install”.
Page 60: Engine Does Not Crank
UENR0612 Symptom Troubleshooting i05963787 Engine Does Not Crank Probable Causes • Battery cables and batteries • Switches and/or circuit breakers • Safety interlock on the application • Starting motor solenoid or starting circuit • Starting motor and/or flywheel ring gear •...
Page 61 UENR0612 Symptom Troubleshooting (Table 25, contd) Troubleshooting Test Steps Values Results 3. Safety Interlock on the Application Safety interlocks Result: A safety interlock is preventing the engine from starting. A. Check that any safety interlock features on the application are in the safe position. Refer to the OEM documentation for de- Disengage the safety interlock if it is safe to do so.
Page 62: Engine Has Early Wear
UENR0612 Symptom Troubleshooting (Table 25, contd) Troubleshooting Test Steps Values Results 6. Engine Accessories and Transmission Engine accesso- Result: The engine accessories and transmission are not ries and A. Ensure free movement of the driveline. transmission Make the necessary repairs. B.
Page 63 UENR0612 Symptom Troubleshooting Table 26 Troubleshooting Test Steps Values Results 1. Contaminated Oil Oil contains fuel Result: The engine oil is contaminated with fuel. A. Check an oil sample for contamination with fuel. Refer to Trou- Investigate the cause. Refer to Troubleshooting, “Oil Con- bleshooting, “Oil Contains Fuel”.
Page 64: Engine Has Mechanical Noise (Knock)
UENR0612 Symptom Troubleshooting (Table 26, contd) Troubleshooting Test Steps Values Results 6. Incorrect Oil Oil specification Result: The oil specification is incorrect. A. Check that the engine is filled with oil of the correct specification. Drain the engine oil system and refill the engine oil sys- Refer to the Operation and Maintenance Manual, “Refill Capacities tem.
Page 65 UENR0612 Symptom Troubleshooting Table 27 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: There are active codes. codes A. Establish communication between the electronic service tool Troubleshoot any active codes before continuing with this and the Electronic Control Module (ECM). Refer to Troubleshoot- procedure.
Page 66 UENR0612 Symptom Troubleshooting (Table 27, contd) Troubleshooting Test Steps Values Results 5. Engine Accessories Engine Result An engine accessory is the source of the noise. accessory A. Attempt to isolate the source of the noise. Repair the engine accessory and/or replace the engine ac- cessory, as necessary.
Page 67: Engine Misfires, Runs Rough Or Is Unstable
UENR0612 Symptom Troubleshooting i05873118 Engine Misfires, Runs Rough or Is Unstable Note: If the fault is intermittent and the fault cannot be duplicated, refer to Troubleshooting, “Power Is Intermittently Low or Power Cutout Is Intermittent”. Note: If the fault only occurs under certain conditions, test the engine under those conditions.
Page 68 UENR0612 Symptom Troubleshooting Table 28 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: There are active codes. codes A. Establish communication between the electronic service tool Troubleshoot any active codes before continuing with this and the Electronic Control Module (ECM). Refer to Troubleshoot- procedure.
Page 69 UENR0612 Symptom Troubleshooting (Table 28, contd) Troubleshooting Test Steps Values Results 4. Throttle Position Sensor/Throttle Switches (if equipped) Electrical Result: The throttle response is not as expected. connections A. Turn the start switch to the ON position. If the maximum no-load speed cannot be obtained refer to Troubleshooting, “Switch Circuits - Test (Throttle Switch)”...
Page 70: Engine Overspeeds
UENR0612 Symptom Troubleshooting (Table 28, contd) Troubleshooting Test Steps Values Results 7. Electronic Unit Injectors Diagnostic Result: There are active diagnostic codes relating to the codes fuel injectors. A. Use the electronic service tool to check for active diagnostic co- des that relate to the electronic unit injectors.
Page 71 UENR0612 Symptom Troubleshooting Probable Causes • Diagnostic codes • Air Intake • Electrical connectors • Fuel supply • Switches Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 30 Troubleshooting Test Steps Values Results 1.
Page 72: Engine Stalls At Low Rpm
UENR0612 Symptom Troubleshooting (Table 30, contd) Troubleshooting Test Steps Values Results 4. Fuel System Inspection Fuel System Result: A defect was found in the fuel system. A. Check that the fuel shut-off valve is in the OPEN position. Make any necessary repairs. B.
Page 73 UENR0612 Symptom Troubleshooting Table 31 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: A code is active or logged. code A. Establish communication between the electronic service tool and Troubleshoot any codes before continuing with this the Electronic Control Module (ECM) . Refer to Troubleshooting, procedure.
Page 74: Engine Top Speed Is Not Obtained
UENR0612 Symptom Troubleshooting (Table 31, contd) Troubleshooting Test Steps Values Results 4. Low Compression (Cylinder Pressure) Result: Low compression is recorded on one or more compression cylinders. A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the fol- lowing list: ·Loose glow plugs...
Page 75 UENR0612 Symptom Troubleshooting Table 32 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: There are active or logged codes. codes A. Establish communication between the electronic service Troubleshoot any codes before continuing with this procedure. tool and the Electronic Control Module (ECM). Refer to Trou- bleshooting, “Electronic Service Tools”, if necessary.
Page 76 UENR0612 Symptom Troubleshooting (Table 32, contd) Troubleshooting Test Steps Values Results 6. Fuel System Inspection Fuel System Result: A defect was found in the fuel system. A. Check that the fuel shut-off valve is in the OPEN position. Make any necessary repairs. B.
Page 77: Engine Vibration Is Excessive
UENR0612 Symptom Troubleshooting (Table 32, contd) Troubleshooting Test Steps Values Results 8. Low Compression (Cylinder Pressure) Result: Low compression is recorded on one or more compression cylinders. A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the following list: ·Loose glow plugs...
Page 78 UENR0612 Symptom Troubleshooting Table 33 Troubleshooting Test Steps Values Results 1. Engine Supports Engine Result: The mounts and brackets are loose and/or broken. supports A. Inspect the mounts and the brackets while you run the engine Replace the mounts and brackets that are loose and/or through the speed range.
Page 79: Exhaust Has Excessive Black Smoke
UENR0612 Symptom Troubleshooting (Table 33, contd) Troubleshooting Test Steps Values Results 4. Electronic Unit Injectors Diagnostic Result: There are active diagnostic codes for the fuel codes injectors A. Use the electronic service tool to check for active diagnostic co- des that relate to the electronic unit injectors. Troubleshoot the active diagnostic codes.
Page 80 UENR0612 Symptom Troubleshooting Table 34 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Engine Derate Result: A diagnostic code is present. or Diagnostic Note: Certain diagnostic codes and/or event codes may cause Codes Troubleshoot the code. Refer to Troubleshooting, “Diagnostic poor performance.
Page 81 UENR0612 Symptom Troubleshooting (Table 34, contd) Troubleshooting Test Steps Values Results 5. Turbocharger Turbocharger Result: There is a fault on the turbocharger. Note: The turbocharger that is installed on the engine is a non- Repair the turbocharger or replace the turbocharger. Refer to serviceable item.
Page 82: Exhaust Has Excessive White Smoke
UENR0612 Symptom Troubleshooting (Table 34, contd) Troubleshooting Test Steps Values Results 7. Electronic Unit Injectors Diagnostic Result: There are active diagnostic codes for the fuel codes injectors A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors. Troubleshoot the active diagnostic codes.
Page 83 UENR0612 Symptom Troubleshooting Table 35 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic codes Result: There are active diagnostic codes. A. Establish communication between the electronic service tool Troubleshoot any active codes before continuing with and the Electronic Control Module (ECM) . Refer to Troubleshoot- this procedure.
Page 84 UENR0612 Symptom Troubleshooting (Table 35, contd) Troubleshooting Test Steps Values Results 6. Fuel Quality Fuel Result: The fuel quality is not OK. A. Check the fuel quality. Refer to Systems Operation, Testing, and Drain the fuel system and replace the fuel filters. Refer Adjusting, “Fuel Quality - Test”.
Page 85: Exhaust System Contains Coolant
UENR0612 Symptom Troubleshooting (Table 35, contd) Troubleshooting Test Steps Values Results 8. Low Compression (Cylinder Pressure) Low compression Result: Low compression is recorded on one or more cylinders. A. Perform a compression test. Refer to Systems Operation, Test- ing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the following list: ·Loose glow plugs...
Page 86: Exhaust System Contains Oil
UENR0612 Symptom Troubleshooting Table 36 Troubleshooting Test Steps Values Results 1. EGR cooler EGR Cooler Result : The EGR cooler has a leak. A. Check the EGR cooler for leaks for utilizing the “On Engine Repair: Replace the EGR cooler. Refer to the Disassembly Test Procedure”...
Page 87 UENR0612 Symptom Troubleshooting Table 37 Troubleshooting Test Steps Values Results 1. Extended Idle Times Idle times Result The idle times are extensive. A. Extended idle times will allow oil to pass into the exhaust Reduce the idle times. system. Result The idle times are not extensive. Proceed to Test Step 2.
Page 88: Fuel Consumption Is Excessive
UENR0612 Symptom Troubleshooting i05874208 Fuel Consumption Is Excessive Probable Causes • Diagnostic codes • Misreading of fuel level • Fuel leakage • Fuel quality • Quality of oil • Engine accessories and transmission • Coolant temperature • Prolonged operation at idle speed •...
Page 89 UENR0612 Symptom Troubleshooting (Table 38, contd) Troubleshooting Test Steps Values Results 3. Fuel Leakage Fuel leaks Result: Evidence of a fuel leak is found. A. Check the engine for signs of fuel leakage. Repair or replace the component that is leaking fuel. Result: No evidence of a fuel leak is found.
Page 90 UENR0612 Symptom Troubleshooting (Table 38, contd) Troubleshooting Test Steps Values Results 7. Coolant Temperature Coolant Result: The water temperature regulator is not operating temperature correctly. Note: The operating temperature of the engine will affect the rate of fuel consumption. Operation of the engine below the correct Replace the water temperature regulator.
Page 91: Fuel Contains Water
UENR0612 Symptom Troubleshooting (Table 38, contd) Troubleshooting Test Steps Values Results 11. Cooling Fan Cooling fan Result: The cooling fan is operating excessively. Excessive operation of the cooling fan will increase fuel Repair or replace the faulty cooling fan components. consumption.
Page 92: Fuel Rail Pressure Problem
UENR0612 Symptom Troubleshooting Table 40 Troubleshooting Test Steps Values Results 1. Drain the Fuel/Water Separator Bowl Fuel/water Result: The “Water-In-Fuel” warning disappears within 1 separator minute. A. Turn the ignition key to the OFF position. Proceed to Test Step 2. B.
Page 93 UENR0612 Symptom Troubleshooting (Table 41, contd) Diagnostic Trouble Codes for the Fuel Rail Pressure J1939 Description Notes Code 157-2 Engine Injector Metering The ECM detects one of the following conditions: Rail #1 Pressure : Erratic, The amount of fuel delivered by the high-pressure fuel pump is greater than 480 mL/min (16.3 oz/min) Intermittent, or Incorrect for at least 2 seconds while the engine is at low idle.
Page 94 UENR0612 Symptom Troubleshooting Probable Causes • Diagnostic trouble codes • Electrical connectors • Fuel filters • Fuel rail pressure sensor • Fuel system inspection • Fuel rail Pressure Relief Valve (PRV) • High-pressure fuel pump This document has been printed from SPI2. NOT FOR RESALE...
Page 95 UENR0612 Symptom Troubleshooting Recommended Actions Table 42 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic codes Result: One of the diagnostic codes listed in Table 41 is active. A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Proceed to Test Step 2.
Page 96 UENR0612 Symptom Troubleshooting (Table 42, contd) Troubleshooting Test Steps Values Results 4. Fuel Rail Pressure Sensor Pressure sensor Result: The “Fuel Rail Pressure (absolute)” is more than 5,000 kPa (725 psi). A. Make sure that the engine has been shut down for at least 10 minutes.
Page 97 UENR0612 Symptom Troubleshooting Illustration 21 g02859420 This document has been printed from SPI2. NOT FOR RESALE...
Page 98: Fuel Temperature Is High
UENR0612 Symptom Troubleshooting Table 43 Troubleshooting Test Steps Values Results 6. Fuel Rail Pressure Relief Valve (PRV) Fuel in container Result: Fuel is present in the container. A. Turn the keyswitch to the OFF position. Install a replacement fuel manifold. Refer to Disassem- bly and Assembly, “Fuel Manifold (Rail) - Remove and B.
Page 99: Inlet Air Is Restricted
UENR0612 Symptom Troubleshooting i06017534 Inlet Air Is Restricted The Electronic Control Module (ECM) detects a fault with the air flow through the air filter. If the air flow has been restricted, the ECM will generate one of the following codes: Table 44 Code for Inlet Air Restriction J1939...
Page 100: Intake Manifold Air Pressure Is High
UENR0612 Symptom Troubleshooting i05955263 Intake Manifold Air Pressure Is High This procedure covers the following diagnostic code: Table 46 Diagnostic Trouble Codes for High Intake Manifold Air Pressure Description J1939 Code Notes 1127-16 Engine Turbocharger 1 Boost Pressure : High - moderate The Electronic Control Module (ECM) detects that the ac- severity (2) tual intake manifold air pressure is greater than the desired...
Page 101: Intake Manifold Air Pressure Is Low
UENR0612 Symptom Troubleshooting Table 47 Troubleshooting Test Steps Values Results 1. Air Inlet and Exhaust Restrictions Air inlet and ex- Result: Defects found in the air inlet or exhaust systems. haust system A. Check the air filter for damage. Repair any defects. Replace damaged components. B.
Page 102 UENR0612 Symptom Troubleshooting Probable Causes • Intake air filter • Air intake system • Wastegate regulator • Turbocharger Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Table 49 Troubleshooting Test Steps Values Results 1.
Page 103: Intake Manifold Air Temperature Is High
UENR0612 Symptom Troubleshooting i05955273 Intake Manifold Air Temperature Is High The Electronic Control Module (ECM) monitors the intake manifold air for excessive temperature. Use this procedure to determine the cause of high intake manifold air temperature. Probable Causes • Coolant level •...
Page 104: Nrs Mass Flow Rate Problem
UENR0612 Symptom Troubleshooting (Table 50, contd) Troubleshooting Test Steps Values Results 3. Cooling Fan Cooling fan Result: The cooling fan is not operating correctly. A. Check the operation of the cooling fan. Investigate the cause of the incorrect fan operation Note: A fan that is not turning at the correct speed can result Result: The cooling fan is operating correctly.
Page 105 UENR0612 Symptom Troubleshooting Table 51 Diagnostic Trouble Codes J1939 Code Code Description Comments 3358-10 Engine Exhaust Gas Recirculation 1 Intake Pressure : Abnormal Rate of The ECM detects an air leak in the Exhaust Change Gas Recirculation (EGR) system. The warning lamp will flash. The engine may be derated.
Page 106 UENR0612 Symptom Troubleshooting Table 52 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic codes Result: A diagnostic code for the EGR valve is active or logged. A. Connect the electronic service tool to the diagnostic connec- tor. If necessary, refer to Troubleshooting, “Electronic Service Rectify the EGR valve code.
Page 107: Oil Consumption Is Excessive
UENR0612 Symptom Troubleshooting i05955289 Oil Consumption Is Excessive Probable Causes • Misreading oil level • Oil leaks • Engine crankcase breather • Oil level • Air intake and exhaust system • Turbocharger • Low compression (cylinder pressure) Recommended Actions Note: The procedures have been listed in order of probability.
Page 108 UENR0612 Symptom Troubleshooting (Table 53, contd) Troubleshooting Test Steps Values Results 3. Engine Crankcase Breather Breather Result: The engine crankcase breather is blocked or restricted. A. Check the engine crankcase breather for blockage or restrictions. Clear the blockage or restriction. B.
Page 109: Oil Contains Coolant
UENR0612 Symptom Troubleshooting (Table 53, contd) Troubleshooting Test Steps Values Results 6. Turbocharger Turbocharger Result: The oil drain for the turbocharger is blocked or restricted. Note: The turbocharger that is installed on this engine is a nonserviceable item. If any mechanical fault exists, then the Remove the blockage or restriction.
Page 110 UENR0612 Symptom Troubleshooting Table 54 Troubleshooting Test Steps Values Results 1. Engine Oil Cooler Oil level Result: Evidence of coolant in the oil system is identified. A. Drain the engine lubricating oil and coolant from the engine. Install a new oil cooler. Refer to Disassembly and Assembly, Check for leaks in the oil cooler assembly.
Page 111: Oil Contains Fuel
UENR0612 Symptom Troubleshooting (Table 54, contd) Troubleshooting Test Steps Values Results 3. Cylinder Head Cylinder head Result: The cylinder head is not within specification for flatness. A. Check the cylinder head for flatness. Refer to Systems Op- eration, Testing, and Adjusting, “Cylinder Head - Inspect” for Install a new cylinder head.
Page 112 UENR0612 Symptom Troubleshooting (Table 55, contd) 5055-17 Engine Oil Viscosity : Low - least severe (1) The Electronic Control Module (ECM) calculates that the amount of fuel in the engine oil is high. If equipped, the warning lamp will come on. 5055-18 Engine Oil Viscosity : Low - moderate severity (2) The ECM detects that the amount of fuel in the engine oil is very...
Page 113 UENR0612 Symptom Troubleshooting Table 57 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: A 5055 diagnostic code is active. codes A. Connect the electronic service tool to the diagnostic Proceed to Test Step 2. connector. Result: A 5055 diagnostic code is not active. B.
Page 114: Oil Pressure Is Low
UENR0612 Symptom Troubleshooting i05673615 Oil Pressure Is Low This procedure covers the following diagnostic code: Table 58 Diagnostic Trouble Codes for Low Engine Oil Pressure J1939 Description Notes Code 100-17 Engine Oil Pressure : Low The Electronic Control Module (ECM) detects that the engine oil pressure is low. - least severe (1) The engine speed is greater than 500 RPM.
Page 115 UENR0612 Symptom Troubleshooting Table 59 Troubleshooting Test Steps Values Results 1. Visible Leaks Visible leaks Result: There are visible oil leaks. A. Thoroughly inspect the engine for oil leaks. Repair any leaks. Result: There are no visible oil leaks Proceed to Test Step 2. 2.
Page 116 UENR0612 Symptom Troubleshooting (Table 59, contd) Troubleshooting Test Steps Values Results 6. Engine Oil Relief Valve Damage Result: The engine oil relief valve is damaged. A. Inspect the engine oil relief valve for damage. Replace the oil relief valve. Refer to Disassembly and Assem- bly, “Engine Oil Relief Valve - Remove and Install”.
Page 117: Power Is Intermittently Low Or Power Cutout Is Intermittent
UENR0612 Symptom Troubleshooting (Table 59, contd) Troubleshooting Test Steps Values Results 11. Engine Oil Pump Oil pump Result: A component in the oil pump is not within specification. A. Inspect the components of the engine oil pump for exces- sive wear. Repair the oil pump or replace the oil pump, if necessary.
Page 118 UENR0612 Symptom Troubleshooting Table 60 Troubleshooting Test Steps Values Results 1. Diagnostic Codes Diagnostic Result: There are active or logged codes. codes A. Establish communication between the electronic service Troubleshoot any codes before continuing with this procedure. tool and the Electronic Control Module (ECM). Refer to Trou- Refer to Troubleshooting, “Diagnostic Trouble Codes”.
Page 119: Valve Lash Is Excessive
UENR0612 Symptom Troubleshooting (Table 60, contd) Troubleshooting Test Steps Values Results 4. Fuel System Inspection Fuel System Result: A defect was found in the fuel system. A. Check that the fuel shut-off valve is in the OPEN position. Make any necessary repairs. B.
Page 120 UENR0612 Symptom Troubleshooting Table 61 Troubleshooting Test Steps Values Results 1. Lubrication Lubrication Result: The oil flow to the valve mechanism is insufficient. A. Remove the valve mechanism cover. Refer to Disassembly Make sure that the passages for the engine oil are clear. and Assembly, “Valve Mechanism Cover - Remove and In- stall”...
Page 121: Circuit Tests
UENR0612 Circuit Tests Circuit Tests i06008869 Data Link - Test Use this procedure if a fault is suspected in the CAN data link. This procedure also covers the following diagnostic codes: Table 62 Diagnostic Trouble Codes for the CAN Data Link J1939 Description Notes...
Page 122 UENR0612 Circuit Tests Illustration 22 g03600780 Typical example of the schematic for the CAN data link Illustration 23 g03600802 Typical view of the pin locations on the P1 connector (46) CAN + (47) CAN - This document has been printed from SPI2. NOT FOR RESALE...
Page 123 UENR0612 Circuit Tests Table 63 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged Result: A damaged wire or damaged connector was found. wire or A. Turn the keyswitch to the OFF position. connector Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic B.
Page 124: Ecm Memory - Test
UENR0612 Circuit Tests (Table 63, contd) Troubleshooting Test Steps Values Results 3. Check the Data Link Wiring Less than 5 Result: At least one of the resistance measurements is Ohms greater than 5 Ohms - there is an open circuit or high resist- A.
Page 125 UENR0612 Circuit Tests (Table 64, contd) 1221-2 Continuously Monitored Systems Support/Status ; Erratic, The ECM continuously monitors the operating conditions of Intermittent, or Incorrect the engine. If there is an irregularity that is not detected by the engine sensor diagnostics, this code will become active.
Page 126 UENR0612 Circuit Tests Table 65 Troubleshooting Test Steps Values Results 1. Check for Active or Recently Logged Diagnostic Codes Diagnostic Result: A 1221-2 diagnostic code is active or recently codes logged. A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, “Electronic Service Tools”.
Page 127: Electrical Power Supply - Test
UENR0612 Circuit Tests (Table 65, contd) Troubleshooting Test Steps Values Results 4. Re-Flash the ECM Diagnostic Result: The diagnostic code is no longer active. codes A. Ensure that the correct rating of flash file for the engine is Use the electronic service tool to clear all logged diagnostic installed.
Page 128 UENR0612 Circuit Tests Table 66 Diagnostic Trouble Codes for the Electrical Power Supply Circuit 168-3 Battery Potential / Power Input 1 : Voltage This code indicates that the battery circuit to the ECM has excessive voltage while the Above Normal engine is running.
Page 129 UENR0612 Circuit Tests Illustration 24 g03722958 Schematic diagram for the electrical power supply circuit Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 25 g03722982 View of the pin locations on the P1 connector for the electrical power supply circuit (1) Battery+ (2) Battery ground...
Page 130 UENR0612 Circuit Tests Table 67 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. A or connector fuse is blown. A. Check the fuses. Repair the damaged wire or the damaged connector. Replace B.
Page 131: Glow Plug Starting Aid - Test
UENR0612 Circuit Tests i06011752 Glow Plug Starting Aid - Test This procedure covers the following diagnostic codes: Table 68 Diagnostic Trouble Codes for the Glow Plug Start Aid Circuit J1939 Description Notes Code 676-5 Engine Glow Plug Relay : Current Below The Electronic Control Module (ECM) detects a low current condition in the control circuit Normal for the Glow plug Control Unit (GCU) for at least 0.7 seconds.
Page 132 UENR0612 Circuit Tests Illustration 26 g03770598 Schematic diagram for the glow plug starting aid circuit Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 27 g02671559 View of the pin locations on the P1 connector for the Glow Plug Control unit (GCU) (22) GCU diagnostic return (52) GCU control signal...
Page 133 UENR0612 Circuit Tests Navigate to the following menu options in the electronic service tool in order to access the “Glow Plug Starting Aid Override” : • Diagnostics • Diagnostic Tests • Override Parameters Table 69 Troubleshooting Test Steps Values Results 1.
Page 134 UENR0612 Circuit Tests (Table 69, contd) Troubleshooting Test Steps Values Results 3. Check the Glow Plug for the Suspect Cylinder Resistance Result: The measurement indicates an open circuit between the glow plug and the ground point. A. Turn the keyswitch to the OFF position. The glow plug is faulty.
Page 135 UENR0612 Circuit Tests (Table 69, contd) Troubleshooting Test Steps Values Results 6. Check that the GCU is Receiving the Correct Voltage 10 V to 14 V Result: The measured voltage is not within the expected range. A. Turn the keyswitch to the OFF position. Check the fuse for the GCU.
Page 136 UENR0612 Circuit Tests (Table 69, contd) Troubleshooting Test Steps Values Results 9. Create a Short Circuit at the Harness Connector for the Diagnostic Result: A 676-6 diagnostic code is active with the jumper codes installed. A. Turn the keyswitch to the OFF position. Install a replacement GCU.
Page 137: Idle Validation - Test
UENR0612 Circuit Tests (Table 69, contd) Troubleshooting Test Steps Values Results 12. Check the GCU control Wire for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is not within the expected range. A. Turn the keyswitch to the OFF position. There is a short circuit in the wiring between the GCU connec- B.
Page 138 UENR0612 Circuit Tests • The engine will default to limp home mode. • If the engine speed is higher than the speed in limp home mode, the engine will decelerate to limp home mode. • If the engine speed is lower than the speed in limp home mode, the engine speed will remain at the current speed.
Page 139 UENR0612 Circuit Tests Illustration 29 g03771038 Schematic diagram for the Idle Validation Switch (IVS) switch circuit Illustration 30 g03771057 View of the pin locations on the P1 connector for the IVS circuit (42) IVS 2 (76) IVS 1 This document has been printed from SPI2. NOT FOR RESALE...
Page 140 UENR0612 Circuit Tests Table 71 Troubleshooting Test Steps Values Results 1. Check for Active Diagnostic Codes Diagnostic Trouble Result: There is an active or logged , 558-2 or Codes 2970-2 diagnostic code. A. Establish communication between the electronic service tool and the ECM.
Page 141 UENR0612 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 3. Check the IVS Threshold Switch operation Result: The IVS switch operates within the “Idle Validation Min OFF Threshold” and the “Idle Vali- A. Connect the electronic service tool to the diagnostic connector. dation Max ON Threshold”...
Page 142 UENR0612 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 6. Check that the IVS is Grounded 7.9 V to 12.2 V Result: The voltage is within the expected range. A. Disconnect the IVS harness connector. Proceed to Test Step 9. B.
Page 143 UENR0612 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 9. Check the IVS at the Sensor Less than 10 Ohms at Result: The IVS indicates the expected low idle. resistance. A. Turn the keyswitch to the OFF position. Greater than 2000 Ohms No fault is indicated at this time.
Page 144: Indicator Lamp - Test
UENR0612 Circuit Tests (Table 71, contd) Troubleshooting Test Steps Values Results 11. Use the Electronic Service Tool to Reset the IVS Threshold Result: The fault is cleared after programming Limits the new calculated values. The electronic service tool can be used to change the “Idle Valida- Return the engine to service.
Page 145 UENR0612 Circuit Tests (Table 72, contd) Diagnostic Trouble Codes for the Indicator Lamps J1939 Description Notes Code 623-6 Red Stop Lamp : Current Above Normal The ECM detects a high current condition in the circuit for the shutdown lamp. 624-5 Amber Warning Lamp : Current Below Normal The ECM detects a low current condition in the circuit for the warning lamp.
Page 146 UENR0612 Circuit Tests (Table 73, contd) Lamp Outputs (Typical Application) Lamp Default Output Terminal Wait to Start Lamp J1/P1:50 Low Oil Pressure Lamp J1/P1:69 Diesel Particulate Filter (DPF) Lamp J1/P1:94 DPF Disabled Lamp J1/P1:48 Testing the Circuits The ECM briefly activates the lamps when the keyswitch is turned from OFF to ON.
Page 147: Injector Data Incorrect - Test
UENR0612 Circuit Tests i06014480 Injector Data Incorrect - Test This procedure covers the following codes: Table 75 Diagnostic Trouble Codes for “ “ Injector Data Incorrect” ” J1939 Code Description Notes 630-2 Calibration Memory : Erratic, Intermittent, or Incorrect The Electronic Control Module (ECM) detects one of the fol- lowing conditions.
Page 148 UENR0612 Circuit Tests Table 76 Troubleshooting Test Steps Values Results 1. Check for Diagnostic Codes That Are Related to this Diagnostic Result: A 630-2 diagnostic code is active. Procedure codes Proceed to Test Step 2. A. Connect the electronic service tool to the diagnostic connector.
Page 149 UENR0612 Circuit Tests (Table 76, contd) Troubleshooting Test Steps Values Results 4. Check the Oxygen Sensor for Faults 10 V to 14 V Result: There are no diagnostic codes for the oxygen sensor. A. Connect the electronic service tool to the diagnostic Proceed to Test Step 5.
Page 150: Injector Solenoid - Test
UENR0612 Circuit Tests i06014791 Injector Solenoid - Test This procedure covers the following codes: Table 77 Diagnostic Trouble Codes for the Circuit for the Injector Solenoids J1939 Description Notes Code 651-5 Engine Injector Cylinder #01 : Current These diagnostic codes are designed to indicate an open circuit (low current) in either the Below Normal solenoid or the wiring for the electronic unit injector in the applicable cylinder.
Page 151 UENR0612 Circuit Tests If an open circuit is detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire the injector. If a short circuit is detected, a diagnostic code is generated. The ECM will periodically try to fire the injector.
Page 152 UENR0612 Circuit Tests Table 78 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. A or connector fuse is blown. A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
Page 153 UENR0612 Circuit Tests (Table 78, contd) Troubleshooting Test Steps Values Results 4. Create a Short at the ECM Connector Diagnostic Result: An XXX-6 diagnostic code is active with the jumper codes installed. A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
Page 154 UENR0612 Circuit Tests (Table 78, contd) Troubleshooting Test Steps Values Results 6. Create an Open Circuit at the ECM Connector Diagnostic Result: An XXX-5 diagnostic code is active with the P2 con- Codes nector disconnected. A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
Page 155: Mode Selection - Test
UENR0612 Circuit Tests i05927145 Mode Selection - Test Table 79 Diagnostic Trouble Codes for the Mode Selection Circuit J1939 Description Notes Code 2880-2 Engine Operator Primary Intermediate Speed Select : Erratic, In- The Electronic Control Module (ECM) detects the following termittent, or Incorrect conditions: The signal voltage from the mode selection switch is between...
Page 156 UENR0612 Circuit Tests Illustration 36 g03728025 Typical example of the schematic for the mode selection switch Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 37 g02723018 Typical view of the pin locations on the P1 connector for the mode selection switch (55) Mode selection switch signal (77) Mode selection switch ground...
Page 157 UENR0612 Circuit Tests Table 80 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector was not connector found. A. Thoroughly inspect the terminal connections on the P1/J1 connector. Proceed to Test Step 2.
Page 158: Motorized Valve - Test
UENR0612 Circuit Tests (Table 80, contd) Troubleshooting Test Steps Values Results F. Turn the keyswitch to the OFF position. G. Remove the jumper wire. 5. Check the Voltage at the Switch Connector 4.9 V to 5.1 V Result: The voltage is within the expected range. A.
Page 159 UENR0612 Circuit Tests Table 81 Diagnostic Trouble Codes for the Motorized Valves J1939 Description Notes Code 2791-5 Engine Exhaust Gas Recirculation The Electronic Control Module (ECM) detects the following conditions: (EGR) Valve Control : Current Below Normal A low current condition in the output for the NOx Reduction System (NRS) valve for at least 0.3 seconds.
Page 160 UENR0612 Circuit Tests Illustration 38 g03616796 Schematic diagram for the motorized valves Not all connectors are shown. Refer to the electrical schematic for the machine. Illustration 39 g03616849 Typical view of the pin locations on the J2 connector for the motorized valves. (8) Intake throttle valve position sensor 5 VDC supply (9) NRS valve position sensor 5 VDC supply (24) NRS valve position sensor ground...
Page 161 UENR0612 Circuit Tests Table 82 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. or connector A. Thoroughly inspect connectors for the motorized valves. Repair the damaged wire or the damaged connector. Refer to Troubleshooting, “Electrical Connectors - Inspect”...
Page 162 UENR0612 Circuit Tests (Table 82, contd) Troubleshooting Test Steps Values Results 4. Create a Short Circuit at the Valve Connector Diagnostic Result: An XXXX-6 is active with the jumper installed. codes A. Turn the keyswitch to the OFF position. Reconnect the valve. Start the engine. Check for active diagnostic codes on the electronic service tool.
Page 163: Oxygen Level - Test
UENR0612 Circuit Tests (Table 82, contd) Troubleshooting Test Steps Values Results 7. Create an Open Circuit at the ECM Connector Diagnostic Result: An XXXX-5 diagnostic code is active with the P2 con- codes nector disconnected. A. Turn the keyswitch to the OFF position. The fault is in the wiring between the suspect valve and the B.
Page 164 UENR0612 Circuit Tests (Table 83, contd) 3217-5 Aftertreatment #1 Intake O2 : Current Below Normal The Electronic Control Module (ECM) detects a fault in the cir- cuit for the oxygen sensor. 3217-6 Aftertreatment #1 Intake O2 : Current Above Normal The fault detected is either an open circuit or short circuit in the current pump, the ground, the current adjust, the voltage signal or the heater circuit.
Page 165 UENR0612 Circuit Tests Illustration 41 g02724356 View of the pin locations on the P1 connector for the oxygen sensor (7) Sensor heating ground (63) Voltage signal (64) Current pump (85) Virtual ground (86) Current adjust Illustration 42 g03114187 View of the pin locations on the harness connector for the oxygen sensor (view from the front) (1) Current pump (2) Virtual ground...
Page 166 UENR0612 Circuit Tests Table 84 Troubleshooting Test Steps Values Results 1. Check for Active or Recently Logged Diagnostic Codes Diagnostic Result: There are other active or recently logged diagnostic co- codes des that are not listed in this procedure. A. Turn the keyswitch to the OFF position. Troubleshoot all other diagnostic codes before returning to this B.
Page 167 UENR0612 Circuit Tests (Table 84, contd) Troubleshooting Test Steps Values Results 3. Check for Active or Recently Logged Diagnostic Codes Diagnostic Result: One of the following diagnostic codes is active or re- codes cently logged: A. Turn the keyswitch to the ON position. If the engine will start, run the engine for 15 minutes.
Page 168 UENR0612 Circuit Tests (Table 84, contd) Troubleshooting Test Steps Values Results 5. Check the Resistance of the Oxygen Sensor Heater 2.4 to 4 Ohms Result: The measured resistance is not within the expected range. A. Turn the keyswitch to the OFF position. Replace the oxygen sensor.
Page 169: Power Take-Off - Test
UENR0612 Circuit Tests (Table 84, contd) Troubleshooting Test Steps Values Results 8. Check the Wiring for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is less than 1 k Ohm. A. Turn the keyswitch to the OFF position. There is a short circuit in the wiring between the oxygen sensor B.
Page 170 UENR0612 Circuit Tests Table 85 Diagnostic Trouble Codes J1939 Code Description Comments Code The Electronic Control Module (ECM) detects one of the following conditions: One of the PTO switches was pressed within 2.5 seconds of the keyswitch being turned One of the PTO switches was pressed for more than 10 seconds. PTO Governor State : Erratic, Inter- 976-2 mittent, or Incorrect...
Page 171 UENR0612 Circuit Tests Illustration 44 g02690278 View of the pin locations on the P1 connector for the PTO switches (9) PTO mode - OFF (10) PTO mode - resume (31) PTO mode - raise (32) PTO mode - lower Table 86 Troubleshooting Test Steps Values Results...
Page 172 UENR0612 Circuit Tests (Table 86, contd) Troubleshooting Test Steps Values Results 3. Check the PTO Mode Switches on the Electronic Service Switch status Result: The status of each switch changes when Tool the switch is operated. A. Turn the keyswitch to the OFF position. The fault appears to be resolved.
Page 173 UENR0612 Circuit Tests (Table 86, contd) Troubleshooting Test Steps Values Results 6. Create at Short Circuit at the Switch Switch status Result: When the jumper wire is connected, the status of the suspect PTO switch is “CLOSED” . A. Turn the keyswitch to the OFF position. When the jumper wire is disconnected, the status of the suspect PTO switch is “OPEN”...
Page 174: Relay - Test (Start Relay)
UENR0612 Circuit Tests i05939117 Relay - Test (Start Relay) This procedure covers the following diagnostic code: Table 87 Diagnostic Trouble Codes for the Starting Motor Relay J1939 Code Description Notes 677-3 Engine Starter Motor Relay : Voltage Above Normal The Electronic Control Module (ECM) detects the following conditions: A short circuit to battery in the circuit for the starting motor relay while no start request is detected.
Page 175 UENR0612 Circuit Tests Illustration 45 g03730757 Schematic diagram for the start relay circuit Not all connectors are shown. Refer to the Electrical Schematic for the application. The starting motor relay supplies battery power to the relay solenoids in the starting motor. This internal relay provides high current battery voltage to the starting motor.
Page 176 UENR0612 Circuit Tests Table 88 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector connector was not found. The fuses are OK. A. Check the fuses. Proceed to Test Step 2. B.
Page 177 UENR0612 Circuit Tests (Table 88, contd) Troubleshooting Test Steps Values Results 3. Create a Short Circuit at the Starting Motor Relay Diagnostic codes Result: A 677-6 diagnostic code was active with the jumper installed. A. Turn the keyswitch to the OFF position. Install a replacement starting motor.
Page 178 UENR0612 Circuit Tests (Table 88, contd) Troubleshooting Test Steps Values Results 6. Check the Wiring Between the Start Relay and the ECM for Greater than 1 k Ohm Result: Each resistance measurement is greater a Short Circuit than 1 k Ohm. A.
Page 179: Relay - Test (Ecm Main Relay)
UENR0612 Circuit Tests (Table 88, contd) Troubleshooting Test Steps Values Results 9. Check the Start Signal Voltage at the ECM Connector 10 V to 14 V Result: The voltage is within the expected range. A. Turn the keyswitch to the OFF position. Proceed to Test Step 10.
Page 180 UENR0612 Circuit Tests Table 89 Diagnostic Trouble Codes J1939 Code Description Comments Code The Electronic Control Module (ECM) detects that the battery supply voltage is still present 0.5 seconds after the shut-off request from the ECM. ECM Main Relay : Not Responding 1485-7 Properly The warning lamp will come on.
Page 181 UENR0612 Circuit Tests Illustration 47 g03729651 Schematic diagram for the ECM main relay Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 48 g02716384 View of the pin locations on the P1 connector for the ignition keyswitch and battery supply circuit (1) Battery+ (2) Battery ground...
Page 182 UENR0612 Circuit Tests Table 90 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector connector was not found. The fuses are OK. A. Check the fuses. Proceed to Test Step 2. B.
Page 183: Sensor Signal (Analog, Active) - Test
UENR0612 Circuit Tests (Table 90, contd) Troubleshooting Test Steps Values Results 3. Check the ECM Main Relay Open circuit Result: The resistance measurement indicates “Open Circuit” A. Turn the keyswitch to the OFF position. Proceed to Test Step 4. B. Disconnect the ECM main relay. Result: The resistance measurement indicates C.
Page 184 UENR0612 Circuit Tests Table 91 Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Description Notes Code 102-3 Engine Intake Manifold #1 The Electronic Control Module (ECM) detects the following conditions: Pressure : Voltage Above Normal The signal voltage from the intake manifold air pressure sensor is greater than 4.92 VDC for at least 0.5 seconds.
Page 185 UENR0612 Circuit Tests (Table 91, contd) Diagnostic Trouble Codes for the Engine Pressure Sensors J1939 Description Notes Code 3251-4 Particulate Trap Differen- The ECM detects that the signal voltage from the DPF differential pressure sensor is less than 0.2 VDC tial Pressure : Voltage Be- for 1.8 seconds.
Page 186 UENR0612 Circuit Tests Illustration 49 g03774823 Schematic diagram for the engine pressure sensors Not all connectors are shown. Refer to the Electrical Schematic for the application. Note: The DPF differential pressure sensor is installed on engines equipped with a wall flow DPF only.
Page 187 UENR0612 Circuit Tests Table 92 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. or connector A. Thoroughly inspect the terminal connections on the P2/J2 Repair the damaged wire or the damaged connector. Replace and P1/J1 ECM connectors.
Page 188 UENR0612 Circuit Tests (Table 92, contd) Troubleshooting Test Steps Values Results 4. Verify the Type of Active Diagnostic Code Diagnostic Result: An XXXX-4 diagnostic code is active for one or more of codes the pressure sensors at this time. A. Turn the keyswitch to the ON position. Wait at least 10 sec- onds for activation of the diagnostic codes.
Page 189 UENR0612 Circuit Tests (Table 92, contd) Troubleshooting Test Steps Values Results 7. Create a Short at the Sensor Connector Diagnostic Result: An XXXX-4 diagnostic code was active with the jumper codes installed. A. Turn the keyswitch to the OFF position. Temporarily connect a new pressure sensor to the harness, but B.
Page 190: Sensor Signal (Analog, Passive) - Test
UENR0612 Circuit Tests i06019084 Sensor Signal (Analog, Passive) - Test This procedure covers the following codes: Table 93 Diagnostic Trouble Codes for the Engine Temperature Sensors J1939 Description Notes Code 105-3 Engine Intake Manifold #1 The Electronic Control Module (ECM) detects the following conditions: Temperature : Voltage Above Normal The signal voltage for the intake manifold temperature sensor is greater than 4.94 VDC for at least 0.5...
Page 191 UENR0612 Circuit Tests (Table 93, contd) Diagnostic Trouble Codes for the Engine Temperature Sensors J1939 Description Notes Code 173-3 Engine Exhaust Gas Tem- The ECM detects the following conditions: perature : Voltage Above Normal The signal from the exhaust gas temperature sensor is greater than 3.6 VDC for at least 1 second. The battery voltage is at least 10 VDC.
Page 192 UENR0612 Circuit Tests This procedure covers open circuit diagnostic codes and short circuit diagnostic codes that are associated with the following sensors: • Intake manifold temperature sensor • Coolant temperature sensor • Exhaust gas temperature sensor • Fuel temperature sensor •...
Page 193 UENR0612 Circuit Tests Illustration 52 g03775307 Schematic diagram for the engine temperature sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic. Note: The engine may be equipped with a combined intake manifold pressure/temperature sensor or an individual intake manifold temperature sensor.
Page 194 UENR0612 Circuit Tests Illustration 54 g02868180 Typical view of the P1 pin locations for the temperature sensors (19) Air inlet temperature sensor signal (20) Air inlet temperature sensor ground (79) DOC inlet temperature sensor ground (80) DOC inlet temperature sensor signal (81) Exhaust gas temperature sensor ground (82) Exhaust gas temperature sensor signal (83) DPF inlet temperature sensor ground...
Page 195: Sensor Supply - Test
UENR0612 Circuit Tests (Table 94, contd) 2. Create a Short at the Sensor Connector Short Circuit Result: The -3 diagnostic code remains active for the sus- Recognized pect sensor. A. Turn the keyswitch to the OFF position. Repair: The fault is in the wiring for the suspect sensor. B.
Page 196 UENR0612 Circuit Tests (Table 95, contd) 3509-2 Sensor Supply Voltage 1 : Erratic, Intermittent, The Electronic Control Module (ECM) detects a fault in the 5 VDC sensor supply or Incorrect circuit supplied on the following pins: J2:8 J2:9 J2:10 J2:11 J2:12 J2:13 The engine will be derated.
Page 197 UENR0612 Circuit Tests Illustration 55 g03620418 Schematic diagram of the 5 VDC supply circuit supplied by the J2 connector. Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 56 g03775432 Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3510-2 diagnostic code applies to the 5 VDC supply in this illustration.
Page 198 UENR0612 Circuit Tests Illustration 57 g03775446 Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3511-2 diagnostic code applies to the 5 VDC supply in this illustration. Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 58 g02727977 Illustration 59...
Page 199: Solenoid Valve - Test
UENR0612 Circuit Tests Table 96 Troubleshooting Test Steps Values Results 1. Determine the Code Diagnostic Result: A -2 diagnostic code is active. Codes A. Connect the electronic service tool to the service tool connector. Note which 5 V supply is reporting the active sensor supply Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
Page 200 UENR0612 Circuit Tests (Table 97, contd) Diagnostic Trouble Codes for the Solenoid Valves J1939 Description Notes Code 1076-2 Engine Fuel Injection The Electronic Control Module (ECM) detects an intermittent open or short circuit er- Pump Fuel Control ror in the control circuit for the fuel metering valve on the high-pressure fuel pump. Valve : Erratic, Intermit- tent, or Incorrect This diagnostic code will not be active if a continuous fault in the circuit is detected.
Page 201 UENR0612 Circuit Tests Illustration 60 g03626007 Schematic diagram for the solenoid valves Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 61 g02351359 Illustration 62 g03086696 View of the pin locations on the P2 connector for the View of the pin locations on the P1 connector solenoid valves (4) Wastegate regulator return...
Page 202 UENR0612 Circuit Tests Table 98 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. A or connector fuse is blown. A. Check the fuses. Repair the damaged wire or the damaged connector. Replace B.
Page 203 UENR0612 Circuit Tests (Table 98, contd) Troubleshooting Test Steps Values Results 4. Create a Short Circuit in the Harness at the Solenoid Diagnostic Result: An XXXX-6 diagnostic code is active when the jumper codes is installed. A. Turn the keyswitch to the OFF position. Temporarily connect a replacement for the suspect valve to the B.
Page 204 UENR0612 Circuit Tests (Table 98, contd) Troubleshooting Test Steps Values Results 7. Check the Wastegate Regulator Return Wire for an Diagnostic Result: The measured resistance is greater than 5 Ohms. Open Circuit codes The fault is in the wiring between the wastegate regulator and A.
Page 205: Speed Control - Test
UENR0612 Circuit Tests i06019791 Speed Control - Test This procedure covers the following codes: Table 99 Diagnostic Trouble Codes for the Analog Throttle Position Sensors J1939 Description Notes Code 91-3 Accelerator Pedal Position 1 : Voltage The Electronic Control Module (ECM) detects that the signal from the throttle position sen- Above Normal sor is greater than the upper diagnostic limit for at least 0.2 seconds.
Page 206 UENR0612 Circuit Tests Illustration 63 g03733275 Schematic diagram for the throttle position sensors Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 64 g02292314 View of the P1 pin locations for the analog throttle position sensors (16) 5 V supply (throttle 1) (17) 5 V supply (throttle 2) (38) Throttle 1 ground...
Page 207 UENR0612 Circuit Tests Table 100 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. or connector A. Turn the keyswitch to the OFF position. Repair the damaged wire or the damaged connector. Replace any blown fuses B.
Page 208 UENR0612 Circuit Tests (Table 100, contd) Troubleshooting Test Steps Values Results 4. Check the Throttle Selection Status with the Electronic Switch status Result: If the status of the throttle selection switch is shown in Service Tool the OFF position, then the throttle 1 has control of the engine speed.
Page 209 UENR0612 Circuit Tests (Table 100, contd) Troubleshooting Test Steps Values Results 7. Create an Open Circuit at the Sensor Connector Diagnostic Result: An XX-4 diagnostic code became active after discon- Codes necting the sensor. A. Turn the keyswitch to the OFF position. Install a replacement sensor.
Page 210: Speed/Timing - Test
UENR0612 Circuit Tests (Table 100, contd) Troubleshooting Test Steps Values Results 10. Check the Sensor Signal Wire for an Open Circuit Less than 5 Result: The measured resistance is greater than 5 Ohms. Ohms A. Turn the keyswitch to the OFF position. There is an open circuit or high resistance in the sensor signal wire between the sensor connector and the P1 connector.
Page 211 UENR0612 Circuit Tests (Table 101, contd) Diagnostic Trouble Codes for the Engine Speed/Timing Sensors J1939 Description Notes Code 723-8 Engine Speed Sensor #2 : Abnormal Frequency, The Electronic Control Module (ECM) detects the following conditions: Pulse Width or Period A loss of signal from the secondary speed/timing sensor for four crankshaft revolutions.
Page 212 UENR0612 Circuit Tests Illustration 65 g03628020 Schematic diagram for the engine speed/timing sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 66 g02648462 View of the pin locations for the speed/timing sensors on the P2 connector (13) Secondary speed/timing sensor 5 V supply (14) Secondary speed/timing sensor signal (28) Secondary speed/timing sensor ground...
Page 213 UENR0612 Circuit Tests Illustration 67 g02648476 View of the sensor locations (1) Primary speed/timing sensor (2) Secondary speed/timing sensor Illustration 68 g02648517 Typical example of the secondary speed/timing sensor (1) Secondary speed/timing sensor ground (3) Secondary speed timing sensor 5 V (2) Secondary speed/timing sensor signal supply This document has been printed from SPI2.
Page 214 UENR0612 Circuit Tests Table 102 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. or connector A. Turn the keyswitch to the OFF position. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic co- B.
Page 215 UENR0612 Circuit Tests (Table 102, contd) Troubleshooting Test Steps Values Results 4. Check the Engine Wiring Harness Less than 5 Result: At least one of the resistance measurements is greater Ohms than 5 Ohms. A. Turn the keyswitch to the OFF position. The fault is in the wiring between the primary speed/timing sen- B.
Page 216 UENR0612 Circuit Tests (Table 102, contd) Troubleshooting Test Steps Values Results 7. Check the Sensor Signal Voltage at the ECM 4.52 to 4.72 V Result: The measured voltage is within the expected range. A. Turn the keyswitch to the OFF position. The fault is in the sensor signal wire between the secondary speed/timing sensor and the P2 ECM connector.
Page 217 UENR0612 Circuit Tests (Table 102, contd) Troubleshooting Test Steps Values Results 9. Check the Crankshaft Timing Ring and the Camshaft Defects Result: Found fault with the crankshaft timing ring or the cam- Position Wheel shaft position wheel A. Inspect the crankshaft timing ring. Refer to Disassembly If necessary, replace the camshaft position wheel.
Page 218: Switch Circuits - Test (Throttle Switch)
UENR0612 Circuit Tests i05946649 Switch Circuits - Test (Throttle Switch) Table 103 Diagnostic Trouble Codes for the Throttle Switch Circuit J1939 Description Notes Code 2880-2 Engine Operator Primary Intermediate Speed Select : Erratic, In- The Electronic Control Module (ECM) detects the following termittent, or Incorrect conditions: The signal voltage from the throttle switch is between 0.35 V and...
Page 219 UENR0612 Circuit Tests Illustration 70 g03734117 Typical example of the schematic for the throttle switch Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 71 g02723018 Typical view of the pin locations on the P1 connector for the throttle switch (55) Throttle switch signal (77) Throttle switch ground...
Page 220 UENR0612 Circuit Tests Table 104 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector was not connector found. A. Thoroughly inspect the terminal connections on the P1/J1 connector. Proceed to Test Step 2.
Page 221: Switch Circuits - Test (Engine Oil Pressure Switch)
UENR0612 Circuit Tests (Table 104, contd) Troubleshooting Test Steps Values Results F. Turn the keyswitch to the OFF position. G. Remove the jumper wire. 5. Check the Voltage at the Switch Connector 4.9 V to 5.1 V Result: The voltage is within the expected range. A.
Page 222 UENR0612 Circuit Tests Table 105 Diagnostic Trouble Codes for the Oil Pressure Switch Description J1939 Code Notes 100-2 Engine Oil Pressure : Erratic, Intermittent, or Incorrect When the keyswitch is in the ON position (engine not run- ning), the oil pressure switch circuit should be closed. This diagnostic code will be active when the Electronic Con- trol Module (ECM) detects the following conditions: The engine is not running.
Page 223 UENR0612 Circuit Tests Illustration 73 g02710319 View of the pin location on the P2 connector for the oil pressure switch (6) Engine oil pressure switch Table 107 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found.
Page 224 UENR0612 Circuit Tests (Table 107, contd) Troubleshooting Test Steps Values Results 3. Create an Open Circuit at the Switch Connector Diagnostic Result: A 100-2 diagnostic code is active with the switch codes disconnected. A. Turn the keyswitch to the OFF position. Replace the oil pressure switch.
Page 225: Switch Circuits - Test (Air Filter Restriction Switch)
UENR0612 Circuit Tests (Table 107, contd) Troubleshooting Test Steps Values Results 6. Create a Short at the ECM Connector Diagnostic Result: A 100-2 diagnostic code is not active with the jumper Codes installed. A. Turn the keyswitch to the OFF position. The fault is in the wiring between the oil pressure switch and B.
Page 226 UENR0612 Circuit Tests If the engine is equipped with an air filter restriction switch, the type of switch that is installed can be either “Normally Open” or “Normally Closed” . The parameter for the type of switch that is installed can be set using the electronic service tool.
Page 227 UENR0612 Circuit Tests Illustration 75 g02716382 View of the pin location on the P1 connector for the air filter restriction switch (87) Air filter restriction switch Table 111 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found.
Page 228 UENR0612 Circuit Tests (Table 111, contd) Troubleshooting Test Steps Values Results 3. Create an Open Circuit at the Switch Connector Diagnostic Result: The fault is cleared with the switch disconnected. codes A. Turn the keyswitch to the OFF position. Replace the air filter restriction switch. Use the electronic service tool to clear all logged diagnostic co- B.
Page 229: Valve Position - Test
UENR0612 Circuit Tests (Table 111, contd) Troubleshooting Test Steps Values Results 6. Check the Ground Wire for the Switch Diagnostic code Result: The fault is cleared with the jumper installed. A. Turn the keyswitch to the OFF position. The fault is in the ground wire between the air filter restriction switch and battery negative.
Page 230 UENR0612 Circuit Tests (Table 112, contd) Diagnostic Trouble Codes for the Valve Position Sensors J1939 Description Notes Code 27-4 Engine Exhaust Gas Recirculation The ECM detects that the signal voltage from the position sensor on the NRS valve is less Valve Position : Voltage Below than 0.2 VDC for at least 0.5 seconds.
Page 231 UENR0612 Circuit Tests Illustration 76 g03636782 Schematic diagram for the valve position sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 77 g03616849 Typical view of the pin locations on the J2 connector for the valve position sensors. (8) Intake throttle valve position sensor 5 VDC supply (9) NRS valve position sensor 5 VDC supply (24) NRS valve position sensor ground...
Page 232 UENR0612 Circuit Tests Table 113 Troubleshooting Test Steps Values Results 1. Verify All Active and Recently Logged Diagnostic Diagnostic Result: None of the preceding diagnostic codes are active or Codes codes recently logged. A. Turn the keyswitch to the ON position. Wait at least 10 sec- The fault may be intermittent.
Page 233 UENR0612 Circuit Tests (Table 113, contd) Troubleshooting Test Steps Values Results 5. Create an Open Circuit at the Valve Connector Diagnostic Result: An XX-3 diagnostic code is active with the valve codes disconnected. A. Turn the keyswitch to the OFF position. Reconnect the connector for the valve.
Page 234: Water In Fuel - Test
UENR0612 Circuit Tests (Table 113, contd) Troubleshooting Test Steps Values Results 8. Create a Short Circuit at the ECM Connector Diagnostic Result: An XX-4 diagnostic code is active with the jumper wire codes installed. A. Turn the keyswitch to the OFF position. The fault is in the wiring for the suspect sensor between the B.
Page 235 UENR0612 Circuit Tests Illustration 78 g03636920 Schematic diagram for the WIF sensor circuit Not all connectors are shown. Refer to the Electrical Schematic for the application. Illustration 79 g02734203 Typical view of the pin location on the P1 connector for the WIF sensor (30) WIF sensor signal This document has been printed from SPI2.
Page 236 UENR0612 Circuit Tests Table 114 Troubleshooting Test Steps Values Results 1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. or connector A. Turn the keyswitch to the OFF position. Repair the damaged wire or the damaged connector. Use the electronic service tool to clear all logged diagnostic co- B.
Page 237 UENR0612 Circuit Tests (Table 114, contd) Troubleshooting Test Steps Values Results 5. Check that the Sensor is Receiving the Correct Voltage Greater than 11 Result: The measured voltage is less than 11 V. A. Turn the keyswitch to the OFF position. The fault is in the switched battery supply wiring to pin 3 on the WIF sensor connector.
Page 238: Service Tool Features
UENR0612 Service Service Cylinder Cutout This test can disable individual cylinders to while the engine is running to help identify cylinders that are performing below the required level. i06021029 Click “Change” for an individual cylinder in order to switch off that cylinder manually. This test can be Service Tool Features used to identify faults by listening to the sound of the engine as a cylinder is disabled.
Page 239: Electronic Service Tool Does Not Communicate
UENR0612 Service Recommended Actions EGR Valve Learn Reset Use this reset when the Exhaust Gas Recirculation Note: The procedures have been listed in order of (EGR) valve is replaced. probability. Complete the procedures in order. Rail Pressure Valve Learn Reset Use this reset when the fuel rail pressure valve is replaced.
Page 240 UENR0612 Service Table 115 Troubleshooting Test Steps Values Results 1. Configuration of the Communications Adapter Communications Result: The correct “Communications Interface Device” adapter is not selected. A. Access “Preferences” under the “Utilities” menu on the configuration electronic service tool. Select the correct “Communications Interface Device” . B.
Page 241: Ecm Software - Install
Note: If you do not have the part number for the flash transfers the flash file from the PC to the ECM. file, use “PTMI” on the Perkins secured website. Use this process to program the engine flash file to Note: You must have the engine serial number in the existing engine ECM.
Page 242: Ecm - Replace
UENR0612 Service i06022850 a. Select the engine ECM under the “Detected ECM - Replace ECMs” . b. Press the “Browse” button in order to select the part number of the flash file that will be programmed into the ECM. NOTICE Keep all parts clean from contaminants.
Page 243: Electrical Connectors - Inspect
UENR0612 Service 7. Download the flash file. i06022909 Electrical Connectors - Inspect a. Connect the electronic service tool to the diagnostic connector. b. Select “WinFlash” from the “Utilities” menu Most electrical faults are caused by poor connections. on the electronic service tool. The following procedure will assist in detecting faults with connectors and with wiring.
Page 244 UENR0612 Service Table 116 Troubleshooting Test Steps Values Results 1. Check Connectors for Moisture and Corrosion Harness, Result: A fault has been found with the harness or the connectors, connectors. A. Inspect all the harnesses. Ensure that the routing of the wiring and seals are harness allows the wires to enter the face of each connector at a Repair the connectors or the wiring, as required.
Page 245 UENR0612 Service (Table 116, contd) Troubleshooting Test Steps Values Results A. Visually inspect each terminal in the connector. Verify that the Use the electronic service tool in order to clear all logged di- terminals are not damaged. Verify that the terminals are correctly agnostic codes and then verify that the repair eliminates the aligned in the connector and verify that the terminals are correctly fault.
Page 246: Injector Code - Calibrate
UENR0612 Service Table 117 Troubleshooting Test Steps Values Results 4. Perform a Pull Test on Each Wire Terminal Connection Pull test OK Result: A wire has been pulled from a terminal or a terminal has been pulled from the connector in the 30 N (6.7 lb) pull A.
Page 247 UENR0612 Service Exchanging electronic unit injectors can help determine if a combustion problem is in the electronic unit injector or in the cylinder. If two electronic unit injectors that are currently installed in the engine are exchanged between cylinders, the injector codes must also be exchanged.
Page 248: Index
Probable Causes ......... 43 Electronic Service Tools ........6 Recommended Actions........ 43 Optional Service Tools ........7 Cylinder Is Noisy..........45 Perkins Electronic Service Tool..... 7 Probable Causes ......... 45 Required Service Tools ........7 Recommended Actions........ 45 Electronic System Overview......9 Engine Cranks but Does Not Start....
Page 249 UENR0612 Index Section Recommended Actions........ 64 Important Safety Information......5 Engine Misfires, Runs Rough or Is Unstable... 67 Overview............5 Probable Causes ......... 67 Troubleshooting ..........6 Recommended Actions........ 67 Glow Plug Starting Aid - Test ......131 Engine Monitoring System....... 19 Engine Overspeeds.........
Page 250 UENR0612 Index Section Oxygen Level - Test ........163 Recommended Actions.......119 Valve Position - Test ........229 Power Is Intermittently Low or Power Cutout Is Intermittent ..........117 Water in Fuel - Test........234 Probable Causes ........117 Welding Precaution ........... 6 Recommended Actions.......117 Power Take-Off - Test ........
Page 251 This document has been printed from SPI2. NOT FOR RESALE...

This manual is also suitable for:

854e-e34ta

Perkins 854F-E34T Troubleshooting Manual

Introduction

Troubleshooting Section

Electronic System Overview

Configuration Parameters

Configurationparameters

Diagnostic Trouble Codes

Diagnostictrouble Codes

Symptom Troubleshooting

Circuit Tests

Service

Indexsection

Quick Links

Troubleshooting

Related Manuals for Perkins 854F-E34T

Summary of Contents for Perkins 854F-E34T

This manual is also suitable for:

Table of Contents