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Perkins 1204-E44TA Troubleshooting Manual
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Perkins 1204-E44TA Troubleshooting Manual

Perkins 1204-E44TA Troubleshooting Manual

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UENR4469-36 (en-us)
March 2022
Troubleshooting
1204F-E44TA and 1204F-E44TTA
Engines
Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE

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Summary of Contents for Perkins 1204-E44TA

  • Page 1 UENR4469-36 (en-us) March 2022 Troubleshooting 1204F-E44TA and 1204F-E44TTA Engines Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 2 In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 3 Engine Misfires, Runs Rough or Is Unstable..147 Sensor Signal (Analog, Passive) - Test ....390 Engine Overspeeds........... 153 Sensor Supply - Test ......... 399 Engine Shutdown Occurrence......156 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 4 (DCU))............509 ECM - Replace ..........510 Electrical Connectors - Inspect ......511 Injector Code - Calibrate ........517 SCR Inducement Emergency Override ....518 Index Section Index..............521 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 5 • Control of the Selective Catalyst Reduction (SCR) exhaust stream. system • Control of particulate emissions via the Clean Emission Module (CEM) • Applications control system interface • Fault detection and reporting Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 6 Do NOT use electrical components (ECM or sensors) or electronic component grounding points for ground- After connecting the electronic service tool to an ing the welder. engine, the following codes are displayed: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 7 The Electronic Service Tool can also be used to • Data link communications perform the following functions: • Diagnostic tests • Sensor calibrations • Programming of flash files and injector trim codes Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 8 USB port on computers that are not equipped with an RS232 serial port. 3. Connect cable (4) between the “DATA LINK” end of TIPSS adapter (3) and the service tool connector. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 9 CA3 adapter (3) and a USB port of PC (1). 3. Connect cable (4) between the “DATA LINK” end of CA3 adapter (3) and the service tool connector. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 10 Once the ECM has determined the amount of fuel ECM. that is required, the ECM must determine the timing of the fuel injection. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 11 Customer parameters can be used to affect the and Troubleshooting, “Factory Passwords” for characteristics of the engine. Limits are set by the additional information on this subject. factory and by the monitoring system. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 12 UENR4469-36 Electronic System Overview i06926311 Component Location Electronic Control Circuit Diagram Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 13 UENR4469-36 Electronic System Overview Illustration 4 g03725890 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 14 UENR4469-36 Electronic System Overview Electronic control circuit diagram for an engine with a DOC, DPF, and DEF system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 15 UENR4469-36 Electronic System Overview Illustration 5 g03732622 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 16 DPF #1 intake pressure DPF intake pressure (if equipped) DPF inlet temperature sensor DPF #1 intake temperature (if equipped) Note: In the following illustrations, some components have been removed to improve visibility. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 17 (2) Solenoid for the high-pressure fuel pump (6) Barometric pressure sensor (10) Fuel temperature sensor (3) Fuel rail pressure sensor (7) Electronic Control Module (ECM) (4) Intake manifold air temperature sensor (8) Primary speed/timing sensor Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 18 (2) Solenoid for the high-pressure fuel pump (6) Barometric pressure sensor (10) Fuel temperature sensor (3) Fuel rail pressure sensor (7) Electronic Control Module (ECM) (4) Intake manifold air temperature sensor (8) Primary speed/timing sensor Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 19 (14) NRS inlet pressure sensor (17) Secondary speed/timing sensor (12) NRS valve including a position sensor (15) Wastegate regulator (13) NOx Reduction System (NRS) (16) Exhaust Back Pressure Regulator differential pressure sensor (EBPR) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 20 (18) DOC inlet temperature sensor (21) Selective Catalytic Reduction (SCR) (23) Diesel Exhaust Fluid (DEF) injector (19) SCR intake temperature sensor filter (20) Diesel Oxidation Catalyst (DOC) (22) Aftertreatment ID module Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 21 (18) DEF injector (21) SCR intake temperature sensor (24) Soot sensor antennas (19) DPF outlet NOx Sensor (22) DOC intake temperature sensor (20) Aftertreatment ID module (23) DPF intake temperature probe Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 22 Some of the responses are not available For additional information on the SCR system, refer for some of the parameters. Refer to Table 6 . to Systems Operation/Testing and Adjusting. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 23 An active code indicates that a problem is present. Service the active code first. For the appropriate 5. Click the “OK” button. troubleshooting procedure for a particular code, refer to the following troubleshooting procedure: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 24 Locations of the connectors on the engine ECM (1) P2 ECM connector (harness side) (3) Engine ECM (5) P1 ECM connector (harness side) (2) J2 ECM connector (ECM side) (4) J1 ECM connector (ECM side) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 25 The pins on the harness connectors are not Layout of the ECM connector pins serviceable. If a pin or the connector is damaged, the harness must be replaced. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 26 Connectors on the Pump and Electronics Unit (PEU) Illustration 15 g03789278 Locations of the connectors on the PEU (3) Connector for the Dosing Control Unit (4) 31-pin interface connector (DCU) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 27 Illustration 18 g01241538 Connectors for the Termination Resistor Illustration 16 g03789439 Sensor Connectors Analog Sensor Connector (active) Illustration 19 g01355248 Engine Speed/Timing Connector Illustration 17 g01240891 Illustration 20 g01155187 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 28 UENR4469-36 Electronic System Overview Ampseal Connector (typical) Illustration 21 g02219254 Deutsch Connectors (typical) Illustration 22 g02220494 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 29 System Configuration Parameters – System configuration parameters affect the emissions of the engine or the power of the engine. Factory passwords may be required to change the values of system configuration parameters. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 30 Changing the parameters during engine operation can cause the engine to operate erratically and can cause engine damage. Only change the settings of the parameters when the engine is STOPPED. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 31 If “Injector Trim” is displayed below a 268-2 or 630-2 diagnostic code on the electronic service tool, refer to Troubleshooting, “Injector Code - Calibrate”. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 32 Troubleshooting, “Speed Control - Test (Analog) / Speed Con- Accelerator Pedal Position #1 : Volt- Throttle Position Sensor : Voltage Below trol - Test (PWM)” age Below Normal Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 33 Above Normal 168-4 168-4 Battery Potential / Power Input #1 : Troubleshooting, “Electrical Power Supply - Test” Electrical System Voltage : Voltage Be- Voltage Below Normal low Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 34 Ether Injection Control Solenoid : Cur- rent Above Normal rent Above Normal 630-2 268-2 Calibration Memory : Erratic, Inter- Programmed Parameter Fault : Erratic, Troubleshooting, “Configuration Parameters” mittent, or Incorrect Intermittent, or Incorrect (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 35 Cylinder #3 Injector : Current Below rent Below Normal Normal 653-6 Troubleshooting, “Injector Solenoid - Test” Engine Injector Cylinder #03 : Cur- Cylinder #3 Injector : Current Above rent Above Normal Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 36 Troubleshooting, “Solenoid Valve - Test (Solenoid Valves that Engine Turbocharger #1 Wastegate Turbo Wastegate Drive : Current Above Connect to the Engine ECM)” Drive : Current Above Normal Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 37 3226-11 3609-11 Troubleshooting, “Sensor (Data Link Type) - Test” Aftertreatment #1 Outlet NOx : Other Aftertreatment #1 Outlet #1 NOx Level Failure Mode Sensor : Other Failure Mode (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 38 Above Normal 262-3 3509-3 5 Volt Sensor DC Power Supply : Volt- Troubleshooting, “Sensor Supply - Test” Sensor Supply Voltage 1 : Voltage age Above Normal Above Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 39 4334-4 3090-4 Aftertreatment #1 DEF #1 Pressure Aftertreatment #1 DEF Pressure Sensor Troubleshooting, “DEF Pump Pressure Sensor - Test” (absolute) : Voltage Below Normal : Voltage Below Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 40 Aftertreatment #1 Diesel Oxidation Cata- Troubleshooting, “Sensor Signal (Analog, Passive) - Test” Catalyst Intake Gas Temperature : lyst Intake Gas Temperature Sensor : Voltage Above Normal Voltage Above Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 41 Aftertreatment #1 Outlet #1 NOx Level Aftertreatment #1 Outlet Gas Sensor Troubleshooting, “Electrical Power Supply - Test” Sensor Power Supply : Other Failure Power Supply : Other Failure Mode Mode (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 42 Engine Injector Cylinder #01 : Current Normal Below Normal 651-6 Troubleshooting, “Injector Solenoid - Test” Cylinder #1 Injector : Current Above Engine Injector Cylinder #01 : Current Normal Above Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 43 Troubleshooting, “Speed Control - Test (Analog) / Speed Control Accelerator Pedal Position #1 : Volt- Throttle Position Sensor : Voltage Be- - Test (PWM)” age Below Normal low Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 44 Engine Timing Offset fault Mode 262-3 3509-3 5 Volt Sensor DC Power Supply : Volt- Troubleshooting, “Sensor Supply - Test” Sensor Supply Voltage 1 : Voltage age Above Normal Above Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 45 Pressure : Voltage Above Normal 1785-4 3563-4 Intake Manifold Pressure Sensor : Engine Intake Manifold #1 Absolute Troubleshooting, “Sensor Signal (Analog, Active) - Test” Voltage Below Normal Pressure : Voltage Below Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 46 1176-4 Turbocharger #1 Compressor Inlet Engine Turbocharger #1 Compressor Troubleshooting, “Sensor Signal (Analaog, Active) - Test” Pressure Sensor : Voltage Below Inlet Pressure : Voltage Below Normal Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 47 3110-6 4354-6 Troubleshooting, “DEF Line Heater - Test” Aftertreatment #1 DEF Line Heater #1 Aftertreatment #1 DEF Line Heater #1 : Current Above Normal : Current Above Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 48 Pressure : Out of Calibration 412-3 3386-3 Engine Exhaust Gas Recirculation Troubleshooting, “Sensor Signal (Analog, Passive) - Test” EGR Temperature Sensor : Voltage Temperature : Voltage Above Normal Above Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 49 Aftertreatment #1 Identification Num- Aftertreatment #1 Identification : Ab- Troubleshooting, “Aftertreatment Identification Module - Test” ber Module : Abnormal Frequency, normal Frequency, Pulse Width, or Pulse Width, or Period Period (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 50 Sensor : Other Failure Mode Failure Mode 3609-12 3226-12 Troubleshooting, “Sensor (Data Link Type) - Test” Aftertreatment #1 Outlet #1 NOx Lev- Aftertreatment #1 Outlet NOx : Failure el Sensor : Failure (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 51 Aftertreatment #1 DEF Control Mod- Troubleshooting, “DEF Control Module Power - Test” id Control Module Power Supply #1 : ule Power Supply : Current Below Current Below Normal Normal (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 52 J1939 Network #3 : Abnormal Update Update Rate Rate 5856-14 1235-14 Troubleshooting, “Data Link Configuration Status - Test” SAE J1939 Data Link #3 : Special J1939 Network #3 : Special Instruction Instruction Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 53 : High - moderate severity (2) 102-18 E1045 (2) Engine Intake Manifold #1 Pressure Troubleshooting, “Intake Manifold Air Pressure Is Low” Low Intake Manifold Pressure : Low - moderate severity (2) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 54 Engine Fuel Temperature 1 : High - Troubleshooting, “Fuel Temperature Is High” High Fuel Supply Temperature moderate severity (2) 190-0 E362 (3) Engine Speed : High - most severe Troubleshooting, “Engine Overspeeds” Engine Overspeed (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 55 Properly 3031-7 E1441 (2) Aftertreatment #1 DEF Tank Tem- Aftertreatment #1 DEF Tank Tempera- Troubleshooting, “DEF Tank Temperature Is Low” perature : Not Responding Properly ture Not Responding (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 56 High Aftertreatment #1 DEF Pressure 4334-18 Aftertreatment #1 DEF #1 Pressure E931 (2) Troubleshooting, “DEF Pressure Is Low” (absolute) : Low - moderate severity Low Aftertreatment #1 DEF Pressure (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 57 Pressure Relief Valve : High - most sure Relief Valve Active severe (3) 5588-14 E1132 (2) Troubleshooting, “Data Link Configuration Status - Test” Proprietary Network #2 : Special Inconsistent Configuration Detected Instruction (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 58 Troubleshooting, “Oil Pressure Is Low” Low Engine Oil Pressure vere (3) 110-15 E361 (1) Engine Coolant Temperature : High - Troubleshooting, “Coolant Temperature Is High” High Engine Coolant Temperature least severe (1) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 59 (absolute) : High - moderate severity Pressure 4334-18 Aftertreatment #1 DEF #1 Pressure E931 (2) Troubleshooting, “DEF Pressure Is Low” (absolute) : Low - moderate severity Low Aftertreatment #1 DEF Pressure (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 60 Low - moderate severity (2) 412-15 E1092 (1) Engine Exhaust Gas Recirculation Troubleshooting, “NRS Exhaust Gas Temperature Is High” High EGR Temperature Temperature : High - least severe (1) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 61 Loss of Prime 5246-15 E1389 (1) Aftertreatment SCR Operator Induce- Troubleshooting, “SCR Warning System Problem” Aftertreatment #1 SCR Operator ment Severity : High - least severe (1) Inducement (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 62 Low Aftertreatment #1 Diesel Oxida- Aftertreatment 1 Diesel Oxidation Troubleshooting, “Diesel Oxidation Catalyst Has Low Conversion tion Catalyst #1 Conversion Catalyst Conversion Efficiency : Low - Efficiency” Efficiency least severe (1) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 63 • The hour of the last occurrence of the code • The number of occurrences of the code Logged events are listed in chronological order. The most recent event code is listed first. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 64 4. Perform a visual inspection. Inspect the following items: • Fuel supply • Oil level • Oil supply • Wiring • Connectors Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 65 Examples of certain conditions are high engine speed, full load, and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 66 Result: There are no restrictions in the air inlet or exhaust system. For engines with a single turbocharger, proceed to Test Step 5. For engines with two turbochargers, proceed to Test Step (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 67 D. Check that the turbine housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged. E. Check that the turbine blades rotate freely in the turbochargers. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 68 Testing, and Adjusting, “Air in Fuel - Test”. M. Ensure that the fuel system has been primed. Refer to Sys- tems Operation, Testing, and Adjusting, “Fuel System - Prime”. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 69 Transfer Pump Inlet Regulator (TPIR) components (1) Transfer Pump Inlet Regulator (TPIR) (2) TPIR return port Illustration 27 g02485896 Minimum TPIR flow rate in a 12 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 70 TPIR. Connect the TPIR return line to the TPIR. Illustration 29 g02527498 Illustration 30 g02527518 Minimum EFLP flow rate in a 12 VDC system Minimum EFLP flow rate in a 24 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 71 A. Check the valve lash. tion, Testing, and Adjusting, “Engine Valve Lash - Inspect” for the correct procedure. Result: The valve lash is correct. Proceed to Test Step 12. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 72 If the isolation of a cylinder results in a change in the sound that is less notice- able, the cylinder may be operating below normal performance. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 73 • Alternator drive pulley • Alternator bearings • Alternator • Charging circuit Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 74 Proceed to Test Step 5. Result: The alternator bearings are not OK. Repair: Repair the alternator or replace the alternator, as needed. Refer to Disassembly and Assembly for the cor- rect procedure. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 75 Contact the Dealer Solutions Network (DSN). i06151975 Battery Problem Probable Causes • Charging circuit • Batteries • Auxiliary device Recommended Actions Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 76 Belt Tensioner Noise Probable Causes • Belt condition and assembly alignment • Belt tensioner Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 77 Run the engine to test the system. Result: The alignment is visibly correct. Proceed to Test Step 2. Illustration 31 g06276401 (1) Belt tensioner wheel (typical example) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 78 B. Run the engine and check for noise. Illustration 32 g06276469 Typical view of the tensioner (2) Arm (3) Arm case stops (4) Spring case (5) Spring case stops (6) Pulley Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 79 Refer to Disassembly and Assembly, Alternator Belt - Remove and Install. The arm case stops (3) are not contacting or very close to spring case stops (5). Proceed to Test Step 5. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 80 Result: There is evidence of damage to any part of the belt tensioner. I. Inspect the tensioner for excessive bearing wear. Repair: Replace the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner - Remove and Install. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 81 NOx and O2 entering the SCR catalyst. The outlet sensor monitors the NOx and O2 exiting the SCR catalyst. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 82 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. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 83 B. Inspect the cylinder head gasket for faults and any signs of inder Head - Install” . leakage. Result: The cylinder head gasket does not show signs of damage or leakage. Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 84 Engine Coolant Level : Low - Level 2 has fallen below the coolant level sensor for the specified delay time. 111-18 E2143-2 Engine power is derated. The code is logged. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 85 Refer to Troubleshooting, “Event Codes” for information about event codes. Use the electronic service tool in order to view the current trip points for these codes. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 86 • Quality of coolant • Coolant pump • NRS cooler • Cylinder head gasket Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 87 C. Check operation of the pressure relief valve and/or the water Proceed to Test Step 6. temperature regulator. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 88 Disassembly and Assembly, “Water Pump - Install”. the coolant pump. Result The coolant pump is not damaged and the pump is operating correctly. Proceed to Test Step 10. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 89 Avoid contact with skin and eyes. • Coolant temperature sensor • Water temperature regulator Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 90 Refer to Disassembly and Assembly, “Water Temperature Regulator - Re- move and Install”. If the fault is still present, contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 91 Typical breather canister (1) Breather canister cap (2) Filter element (3) Breather canister Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 92 An oil discharge in excess of 0.5 g (0.02 oz) must be investigated. Probable Causes • Breather filter • Engine oil level • One-way valve • Excessive blow-by Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 93 UENR4469-36 Symptom Troubleshooting Illustration 35 g03758596 Typical breather canister (1) Breather canister cap (2) Filter element (2) Breather canister Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 94 If the engine oil is not contaminated, remove the excess oil. Result: The engine oil level is correct. Proceed to Test Step 3. Illustration 36 g03758618 (4) Breather drain hose (5) One-way valve Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 95 • Low compression (cylinder pressure) • Injectors • Pistons and connecting rods Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 96 Proceed to Test Step 4. · Valve springs · Rocker shaft · Bridges · Pushrods · Camshaft followers · Hydraulic lifters Refer to the Disassembly and Assembly for additional information. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 97 B. Inspect the connecting rod bearings for damage and wear. Verify that the repair has eliminated the noise. Result: All components are OK. If the fault is still present, contact the Dealer Solutions Net- work (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 98 Seal the damaged wires with silicone sealant. Cover the sealant with two layers of electrical tape. Follow the Test Steps as directed by the results of each step. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 99 C. Determine the diagnostic trouble code that is active. Illustration 37 g03370573 Illustration 38 g06549965 Typical refractometer reading for DEF in good Typical example of a good test strip result condition Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 100 C. Use the electronic service tool to perform the “Aftertreatment tional diagnostic codes. Refer to Troubleshooting, System Functional Test” Diagnostic Trouble Codes or Troubleshooting, Event Co- des for more information. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 101 Dosing Unit Loss of Prime priming. DEF system pressure deviated from the acceptable limits after the system had successfully primed. Follow the troubleshooting procedure to identify the root cause of the problem. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 102 If the DEF system primes successfully, and the 5392–31 E1370 (2) diagnostic is no longer active, return the engine to service. If the 5392–31 E1370 (2) diagnostic code is still active, contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 103 Complete the procedure in the order in which the steps are listed. Illustration 39 g03790973 Typical view of the Pump and Electronics Unit (PEU) (1) DEF Pump (2) DEF pressure line connector (3) DEF suction line connection Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 104 Proceed to Test Step 6. Note: Possible obstructions are ice, DEF deposits, or debris. Result: An obstruction was not found. Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 105 C. Turn the keyswitch to the OFF position. Remove the DEF pres- sure line from the container immediately to prevent the DEF being sucked back into the line when the DEF system purges. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 106 Repair: Troubleshoot the additional codes. Refer to Trou- bleshooting, “Diagnostic Trouble Codes”. Repeat Test Step 5. Result: The test was not successful. There are no addi- tional codes. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 107 Follow the troubleshooting procedure to identify the root cause of the problem. Table 43 Required Tools Part Description Tool Part Number Tool Gp T402192 Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 108 C. If necessary, replace the DEF tank filler screen or the DEF tank filler cap. D. Use the electronic service tool to perform an “Aftertreatment System Functional Test” . (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 109 Adjusting “Diesel Exhaust Fluid Tank - Flush” After flush procedure completed, proceed to Test Step 12. Result: The DEF is not contaminated. Proceed to Test Step 7. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 110 Typical view of the DEF tank (1) DEF Pump (4) DEF tank header unit (2) DEF Pressure line connection (5) DEF suction line connection (3) DEF suction line connection (6) DEF return line connection Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 111 C. Perform the “Aftertreatment System Functional Test” . Repair: Troubleshoot the additional codes. Confirm that the fault has been eliminated. If the fault is still present, contact the Dealer Solutions Net- work (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 112 Note: Before starting the troubleshooting steps, please ensure that the DEF system (including tank and lines) is fully thawed and is at least half full of DEF. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 113 F. Turn the keyswitch to the ON position. Note: The gauge may take up to 60 seconds to show the correct DEF level. G. Check for a change in the gauge position. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 114 Use the electronic service tool to perform the “Aftertreat- ment System Functional Test” to ensure that the repair eliminates the fault. Repeat this procedure from Test Step 1. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 115 The code is logged. The engine is derated. Follow the troubleshooting procedure to identify the root cause of the problem. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 116 - Inspect” for further information. Result: The connections are corroded and/or are loose. B. Inspect for corrosion or loose wires. Repair: Make the necessary repairs. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 117 Result: The DEF has been replaced. A. Replace the DEF. Refer to Operation and Maintenance Manual, Return the unit to service. “Diesel Exhaust Fluid Tank - Flush” for the correct procedure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 118 Determine the cause of low coolant. Refer to Trouble- shooting, “Low Coolant Level” for additional information. If adding coolant does not correct the fault, proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 119 Cycle the keyswitch. Use the electronic service tool to perform the “Aftertreat- ment System Functional Test” to verify that the repair eliminates the fault. Proceed to Test Step 8. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 120 UENR4469-36 Symptom Troubleshooting Illustration 44 g03701177 (1) Coolant diverter valve Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 121 If the fault is still present, contact the Dealer Solutions Network (DSN). i06155905 Diesel Oxidation Catalyst Has Incorrect Inlet Temperature This procedure is only applicable to engines that have a Diesel Particulate Filter (DPF). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 122 Any contact with hot surfaces can cause severe burns. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 123 Repair: Troubleshoot the error code. Refer to Trouble- shooting, “Service Tool Error Identifiers”. Result: The test failed. No associated diagnostic trouble codes are active. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 124 Result: There is no oil in the exhaust system. Repair: Use the electronic service tool to perform the “HC Dosing Capability Test” . Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 125 (If Equipped) This procedure is only applicable to engines that have a Diesel Particulate Filter (DPF) installed. If the soot load becomes excessive, the ECM activates the applicable code. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 126 Attenuator Engine operation must be kept to a minimum to minimize the amount of soot that is created. Follow the troubleshooting procedure to minimize the amount of engine operation. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 127 If the 3719 (E995) code has been eliminated, proceed to Test Step 9. If the 3719 (E995) code is still present, proceed to Test Step 3. Result: No corrective actions were performed. Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 128 Dealer Solutions Network (DSN). B. Use the electronic service tool to perform the “Cylinder Cutout Result: The “Cylinder Cutout Test” is successful. Test” . Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 129 A. Start the engine and use the electronic service tool to perform Return the unit to service. the “Manual Diesel Particulate Filter Regeneration.” Result: The soot content of the DPF remains high. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 130 Particulate Trap Intake Gas Temperature : Low - moder- E1014 (2) Engine power is derated 30%. The code is logged. The 3242-18 ate severity (2) code remains active until electrical power to the ECM is cycled. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 131 “Motorized Valve - Test”. Proceed to Test Step 5. Result: There are no active diagnostic trouble codes that are associated with the EBPR. Contact the Dealer Solutions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 132 • Low-pressure fuel system • Transfer Pump Inlet Regulator (TPIR) • EFLP flow rate • Return fuel lines • High-pressure fuel system • Starting aids • Low compression (cylinder pressure) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 133 If the DPF frequently collects excessive soot prior to this fault, there may be a faulty cylinder in the engine. Proceed to Test Step 12. Result: All checks are OK. Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 134 Result: There is air in the fuel system. Repair: Prime the fuel system. Refer to Systems Opera- tion, Testing, and Adjusting, “Fuel System - Prime”. Result: The diesel fuel is contaminated. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 135 Transfer Pump Inlet Regulator (TPIR) components (1) Transfer Pump Inlet Regulator (TPIR) (2) TPIR return port Illustration 46 g02485896 Minimum TPIR flow rate in a 12 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 136 TPIR. Connect the TPIR return line to the TPIR. Illustration 48 g02527498 Illustration 49 g02527518 Minimum EFLP flow rate in a 12 VDC system Minimum EFLP flow rate in a 24 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 137 EFLP and the TPIR are not blocked or kinked. EFLP and the TPIR are clear. Repair: Replace the EFLP. If the fault is still present, proceed to Test Step 9. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 138 ECM is installed. If the engine will not start with the suspect ECM, replace the ECM and then check that the engine starts normally. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 139 Note: Possible causes of low compression are shown in the following list: · Loose glow plugs · Faulty piston · Faulty piston rings · Worn cylinder bores · Worn valves · Faulty cylinder head gasket (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 140 Proceed to Test Step 4. tems Operation, Testing, and Adjusting, “Electrical System” for additional information. Result The starting motor solenoid and circuit are not OK. Repair: Make the necessary repairs. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 141 E. If a mechanical problem is suspected, disassemble the en- gine. Refer to the Disassembly and Assembly manual. Inspect the internal components for the following conditions: · Seizure · Broken components · Bent components Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 142 • Leaks in air intake system • Dirt in fuel • Low oil pressure Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 143 Inspect all of the gaskets and the connec- Proceed to Test Step 4. tions. Refer to Systems Operation, Testing, and Adjusting, “Air In- let and Exhaust System” for more information. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 144 Complete the procedures in order. Probable Causes • Active codes and logged codes • Electrical connections • Fuel injection • Fuel quality • Lubrication • Engine accessory • Valve train components Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 145 Refer to Systems Operation, Testing, and Adjust- ing, “Fuel Quality - Test” for the correct procedure. Repair: Replace the fuel. Verify that the repair eliminated the fault. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 146 Refer to Disassembly and Assembly for additional information. C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves. Refer to Disassembly and Assembly for additional information. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 147 • Transfer Pump Inlet Regulator (TPIR) • Electric Fuel Lift Pump (EFLP) • Return fuel lines • Throttle position sensor • CAN data link • High-pressure fuel pump • Low compression (cylinder pressure) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 148 Testing, and Adjusting, “Air in Fuel - Test”. H. Obtain a fuel analysis to confirm that the correct fuel is being used. Refer to Systems Operation/Testing and Adjusting, “Fuel Quality - Test” for the correct procedure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 149 Transfer Pump Inlet Regulator (TPIR) components (1) Transfer Pump Inlet Regulator (TPIR) (2) TPIR return port Illustration 51 g02485896 Minimum TPIR flow rate in a 12 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 150 TPIR. Connect the TPIR return line to the TPIR. Illustration 53 g02527498 Illustration 54 g02527518 Minimum EFLP flow rate in a 12 VDC system Minimum EFLP flow rate in a 24 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 151 A. Use the electronic service tool to check for diagnostic codes Result: The CAN data link is OK. that are related to the CAN data link. Proceed to Test Step 8. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 152 · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Result: The results of the compression test are OK. Proceed to Test Step 11. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 153 Engine Overspeeds This procedure covers the following diagnostic trouble codes: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 154 • Turbocharger or turbochargers • Combustible gases or liquid in the Intake air Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 155 Result: There is combustible liquid in the air intake. Repair: Remove the liquid. Investigate and rectify the cause of liquid ingestion Result: The intake air does not contains combustible gases. Contact the Dealer Solutions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 156 Complete the procedure in the order in which the Engine Shutdown Occurrence steps are listed. Note: The engine is stopped immediately when an emergency stop button is pressed. Probable Causes • Operator • Fuel • Mechanical Failure Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 157 Note: The procedures have been listed in order of • Active codes and logged codes probability. Complete the procedures in order. • Electrical connections • Unstable fuel supply • Switches • Circuit protection • Engine speed/timing Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 158 B. Check any engine shutdown switches and associated wiring. Result: The shutdown switches and wiring are not OK. Repair: Make the necessary repairs, Verify that the repair eliminated the fault. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 159 • Fuel supply • Low compression (cylinder pressure) • Electronic unit injectors Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 160 Result: There is a fault in the data link. control A. Check whether the power mode control is using the Perkins data Repair: Repair the data link, as necessary. link or the CAN data link and then use the appropriate test. Refer to Troubleshooting, “Data Link - Test”...
  • Page 161 · Loose glow plugs · Faulty piston · Faulty piston rings · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 162 • Air intake and exhaust system • Turbocharger or turbochargers • Fuel supply • Transfer Pump Inlet Regulator (TPIR) • Electric Fuel Lift Pump (EFLP) • Return fuel lines Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 163 Repair: Refer to the appropriate circuit test for the type of tion and the calibrated position. throttle that is installed. Result: The throttle signal is OK. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 164 Wait 10 minutes after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 165 Fill and prime the fuel system with fuel of the correct specifica- tion. Refer to Systems Operation, Testing, and Adjusting, “Fuel System - Prime”. Result: The fuel supply is OK. Proceed to Test Step 9. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 166 Transfer Pump Inlet Regulator (TPIR) components (1) Transfer Pump Inlet Regulator (TPIR) (2) TPIR return port Illustration 56 g02485896 Minimum TPIR flow rate in a 12 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 167 TPIR. Connect the TPIR return line to the TPIR. Illustration 58 g02527498 Illustration 59 g02527518 Minimum EFLP flow rate in a 12 VDC system Minimum EFLP flow rate in a 24 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 168 · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Result: The results of the compression test are OK. Proceed to Test Step 13. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 169 Probable Causes • Driven equipment • Engine supports • Low compression (cylinder pressure) • Electronic unit injectors • Individual malfunctioning cylinder Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 170 · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Result: The results of the compression test are OK. Proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 171 Particulate Filter (DPF) has also failed. Perform the • Electronic unit injectors following procedure to diagnose the cause of the black smoke and then investigate the failure of the • Individual malfunctioning cylinder DPF. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 172 Result: The valve lash is correct. For engines with a single turbocharger, proceed to Test Step For engines with twin turbochargers, proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 173 D. Check that the turbine housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged. E. Check that the turbine blades rotate freely in the turbochargers. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 174 · Worn cylinder bores · Worn valves · Faulty cylinder head gasket · Damaged cylinder head Result: The results of the compression test are OK. Proceed to Test Step 8. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 175 If the white smoke persists, there may be a fault. Probable Causes • Diagnostic codes • ECM Flash file • Glow plugs • Ether injection • Coolant temperature Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 176 Repair: Replace the water temperature regulator. Veri- Temperature Regulator - Test”. fy that the repair corrected the fault. Result: The water temperature regulator is operating correctly. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 177 Testing, and Adjusting, “Engine Valve Lash - In- spect” for the correct procedure. Proceed to Test Step 12. Result: The valve lash is correct. Proceed to Test Step 9. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 178 Unit Injector - Remove” and Disassembly and Assembly, “Electronic Unit Injector - Install”. Proceed to Test Step 12. Result: All injectors are OK. Proceed to Test Step 11. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 179 Recovery Procedure” . While the procedure is progressing, check for smoke from the exhaust. Some smoke will be evident during the procedure. The smoke must dissipate before the procedure is completed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 180 B. Inspect the cylinder head gasket for faults and any signs of Head - Install” . leakage. Result: The cylinder head gasket shows signs of damage or leakage. Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 181 • Worn valve guide seals or faulty valve guide seals • Worn valve guides • Worn piston rings Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 182 Result The piston rings are not worn. C. Inspect the pistons and piston rings for wear or damage. Refer Contact the Dealer Solutions Network (DSN). to the “Specifications” manual for further information. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 183 ECM derates the engine in order to reduce the exhaust temperature. The engine is derated only to a level that allows the exhaust temperature to return to an acceptable level. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 184 Note: Information from this histogram is to be used with active and logged diagnostic trouble codes. This histogram is for information only. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 185 Ensure that the flow of air or coolant through the If the procedure did not correct the issue, contact the Dealer ATAAC is adequate. Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 186 • Reduced pressure of intake air • Excessive valve lash • Failure of the primary speed/timing sensor Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 187 B. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine. Result: The fuel quality meets specifications. Proceed to Test Step 5. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 188 · Restrictions the air inlet and exhaust systems. · Damage to lines or hoses Result: The air intake and exhaust system is OK. Proceed to Test Step 9. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 189 Result: The primary speed/timing sensor is operating replaced with an engine speed once the ECM is able to calcu- correctly. late a speed from the signal. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 190 The similarity in color would prevent the ability to differentiate the water from the fuel. Recommended Actions Note: Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 191 Use this procedure to troubleshoot abnormal fuel rail pressure or use this procedure if any of the following diagnostic trouble codes are active. Refer to Troubleshooting, “Diagnostic Trouble Codes” for information about the codes. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 192 • Return fuel lines • Low fuel rail pressure • Transfer Pump Inlet Regulator (TPIR) • Transfer Pump Inlet Regulator (TPIR) Return • Electric Fuel Lift Pump (EFLP) • Return fuel lines Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 193 Fuel Rail Pressure Sensor and on the Suction Control Valve for the High-Pressure Fuel Pump. Repair or replace connectors that are suspect. Result: There are no suspect connectors. Proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 194 Result: Fuel rail pressure is still high after performing the “High Pressure Fuel Pump Calibration” . Run the engine for a minimum of 30 minutes. Proceed to Test Step 7. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 195 Transfer Pump Inlet Regulator (TPIR) components (1) Transfer Pump Inlet Regulator (TPIR) (2) TPIR return port Illustration 62 g02485896 Minimum TPIR flow rate in a 12 V system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 196 TPIR. Connect the TPIR return line to the TPIR. Illustration 64 g02527498 Illustration 65 g02527518 Minimum EFLP flow rate in a 12 V system Minimum EFLP flow rate in a 24 V system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 197 Result: The EFLP is not operating correctly. Refer to Troubleshooting, “Fuel Transfer Pump - Test”. Result: The TPIR return line and the EFLP are OK. Proceed to Test Step 10. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 198 Result: “Fuel Rail Pressure Relief Valve Test” fails Repair: Replace the Fuel Rail Pressure Relief Valve. Refer to Disassembly & Assembly, “Relief Valve (Fuel) - Remove and Install”. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 199 Transfer Pump Inlet Regulator (TPIR) components (1) Transfer Pump Inlet Regulator (TPIR) (2) TPIR return port Illustration 67 g02485896 Minimum TPIR flow rate in a 12 V system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 200 Result: The EFLP is not operating correctly. Repair: Refer to Troubleshooting, “Fuel Transfer Pump - Test”. Result: The TPIR return line and the EFLP are OK. Proceed to Test Step 14. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 201 UENR4469-36 Symptom Troubleshooting Illustration 69 g02527498 Minimum EFLP flow rate in a 12 V system Illustration 70 g02527518 Minimum EFLP flow rate in a 24 V system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 202 Warranty Report, PSR and Snapshot Data as saved in steps 1 and 2. i06160419 Fuel Temperature Is High If either of the following diagnostic trouble codes are active, perform the procedure that follows: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 203 Result: A 174-16 (E363 (2)) diagnostic code is active or logged. B. Use the electronic service tool to check for active or logged codes. Proceed to Test Step 2. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 204 A. Make sure that the fuel tank is not close to a heat source. Repair: Shield the fuel tank from the heat source. Result: The fuel tank is not close to a heat source. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 205 E583(2) 107-16 High - moderate severity (2) The code is logged. The engine power is derated. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 206 Probable Causes Recommended Actions • Turbocharger wastegate Note: The procedures have been listed in order of probability. Complete the procedures in order. • Wastegate regulator Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 207 Note: The downloaded information will be required by the DSN if troubleshooting assistance is required. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 208 A. Use the electronic service tool to check for diagnostic trou- ble codes that relate to the wastegate regulator. Repair: Rectify the cause of any related codes. Refer to Trou- bleshooting, “Diagnostic Trouble Codes”. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 209 • Air intake system • Wastegate regulator • Low battery voltage • Turbocharger or turbochargers Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 210 Result: There are no diagnostic codes that relate to the wastegate regulator. For engines that have a single turbocharger, proceed to Test Step 4. For engines that have twin turbochargers, proceed to Test Step 5. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 211 Intake Manifold Air Temperature Is High The Electronic Control Module (ECM) monitors the intake manifold air for excessive temperature. The following event codes are associated with high intake manifold air temperature: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 212 • Air inlet and exhaust system • Ambient temperature • Altitude • Running condition Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 213 A. Check for the correct operation of the exhaust back pres- Repair: Investigate the EBPR. Refer to Troubleshooting, “Mo- sure regulator. torized Valve - Test”. Result: The EBPR is OK. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 214 Follow the troubleshooting procedure to identify the root cause of the problem. Table 112 (Table 112, contd) Required Tools T400195 Refractometer T401199 Kit - Test Part Description Tool Part Number (continued) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 215 E1410 (2) 4364-2 E946 (2) 4360-16 E947 (1) 4360-17 E947 (2) 4360-18 E2165 (1) 4765-17 5298-17 2180-1 Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 216 Result: A 7105-31 (E1585 (2)) code is active or logged. Proceed to Test Step 15. Result: A 4364–18 (E1309 (2) code is active or logged. Proceed to Test Step 3. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 217 UENR4469-36 Symptom Troubleshooting Illustration 71 g03370573 Typical refractometer reading for DEF in good condition Illustration 72 g06549965 Typical example of a good test strip result Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 218 Refer to Operation and Maintenance Manual, “Diesel Ex- result. haust Fluid Tank - Flush” for the correct procedure. Proceed to Test Step 11. Illustration 73 g06179695 DEF line routing between components Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 219 C. Check all exhaust connections from the turbo outlet to the SCR outlet (tailpipe outlet). Result: There were no exhaust leaks found. D. Check for damage to the exhaust system insulation. Proceed to Test Step 6. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 220 Example of a DEF injector dripping during the prime Example of a good injector spray pattern phase Illustration 77 g06550358 Illustration 75 g06550304 Example of a poor DEF injector spray pattern Example of the DEF dosed quantity Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 221 CAN C data link circuit. Repair: Repair the connectors and/or the wiring. Replace parts, if necessary. The DCU connector is not serviceable. Proceed to Test Step 10. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 222 Note: Do not use abrasive materials or fluids to clean the sensor. Reinstall the sensor. Refer to Disassembly and Assembly for the correct procedure. Proceed to Test Step 10. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 223 Typical example of DEF deposits in the Selective Typical example of a clear SCR mixer Catalytic Reduction (SCR) mixer Illustration 80 g06550824 Typical example of DEF deposits in the SCR mixer Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 224 C. Use the electronic service tool to perform the “Aftertreatment Proceed to Test Step 10. System Functional Test” Result: A 4364-18 (E1309 (2)) with an ETI code of 1 is active. Proceed to Test Step 12. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 225 Repair: Replace the NOx sensors with approved parts. gine Out NOx sensors that are fitted. Result: The NOx sensors are an approved part and the fault is still present. Contact the DSN. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 226 The engine will be derated. The ECM has been powered for at least 2 seconds. The engine has been running for at least 180 seconds. There are no electrical faults on the circuit. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 227 Complete the procedures in order. moderate severity 110-0 E361 (3) Engine Coolant Temperature : High - most severe Probable Causes • Diagnostic codes • Coolant leak or low coolant level • NRS cooler Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 228 (NRS) - Remove and Install”. Engines equipped with a DPF : Contact the Dealer Solu- tions Network (DSN). i06889488 NRS Mass Flow Rate Problem This procedure covers the following diagnostic trouble code: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 229 There are no active codes for the 5 VDC supply. There are no active 27, 157, 411, 1188, 2791, 3358 or 3563 codes. 412-3 or 412-4 codes are not active. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 230 (8) NRS inlet pressure sensor (2) NRS mixer (5) Manifold for the NRS pressure sensors (3) Pipe for the NRS differential pressure (6) NRS cooler sensor (7) NRS differential pressure sensor Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 231 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 232 6 N·m (53 lb in). G. Check the harness for abrasion and pinch points from the NRS components to the ECM. H. Check that any suspect connector is installed correctly. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 233 C. Test the exhaust back pressure regulator. Refer to Trouble- shooting, “Motorized Valve - Test”. Result: The probe on the temperature sensor does not have excessive deposits. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 234 • Misreading oil level • Oil leaks • Engine crankcase breather • Oil level • Air intake and exhaust system • Turbocharger or turbochargers • Low compression (cylinder pressure) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 235 Make sure that the oil is not contaminated with coolant. Refer to Troubleshooting, “Oil Contains Coolant”. Remove the excess oil. Result: The oil level is OK. Proceed to Test Step 5. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 236 “Exhaust System Contains Oil”. Check that the repairs have eliminated the faults. Result: The turbocharger is OK. Proceed to Test Step 8. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 237 Note: The procedures have been listed in order of probability. Complete the procedures in order. Probable Causes • Engine oil cooler • Engine water pump • Cylinder head and gasket • Cylinder block Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 238 Refill the engine oil and coolant. Refer to Operation and Main- tenance Manual for the correct procedure. Result: There is no evidence of damage or leaks. Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 239 Fill the cooling system. Refer to the Operation and Mainte- nance Manual for more information. If coolant is found in the oil again, contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 240 SAE viscosity grades. However, these guidelines stopped to allow fuel pressure to purge before any still provide adequate engine protection. service or repair is performed on the engine fuel lines. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 241 Maintenance Manual, “Engine Oil and Filter - Change”. Result: The shaft seal for the high-pressure fuel pump is OK. If the fault is still present, contact the Dealer Solutions Net- work (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 242 • Low engine oil level • Problem with an electrical connection or with the wiring Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 243 Refer to the Operation and Maintenance Manual for details. The Electronic Control Module (ECM) monitors the engine oil pressure. The following events are associated with low engine oil pressure: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 244 100-1 There are no diagnostic trouble codes for the 5 VDC supply. The engine will be derated. Refer to Illustration 86 for the trip point for the oil pressure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 245 • Bearing clearance Diagnostic code 100-18 Engine Oil Pressure versus Engine Speed Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 246 Repair: Install a new oil filter. Refer to the Operation and Maintenance Manual, “Engine Oil and Filter - Change” for fur- ther information. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 247 Repair: Repair or replace the pressure relief valve, as neces- sary. Refer to Disassembly and Assembly, “Engine Oil Relief Valve - Remove and Install”. Result: The pressure relief valve is OK. Proceed to Test Step 11. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 248 • Intake manifold pressure • Fuel supply • Transfer Pump Inlet Regulator (TPIR) flow • Transfer Pump Inlet Regulator (TPIR) return • Electric Fuel Lift Pump (EFLP) flow • Return fuel lines Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 249 Note: If a fault is suspected with the ECM power or ground Result: Both ECM connectors are correctly installed. connections, refer to Troubleshooting, “Electrical Power Sup- ply - Test”. Proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 250 Testing, and Adjusting, “Air in Fuel - Test”. M. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, “Fuel System - Prime”. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 251 (1) Transfer Pump Inlet Regulator (TPIR) (2) TPIR return port the pump. Illustration 88 g02485896 Minimum TPIR flow rate in a 12 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 252 C. Make sure that the fuel lines between the EFLP and the TPIR are not blocked or kinked. Result: All fuel lines are OK and the EFLP appears to be op- erating correctly. Proceed to Test Step 8. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 253 UENR4469-36 Symptom Troubleshooting Illustration 90 g02527498 Minimum EFLP flow rate in a 12 VDC system Illustration 91 g02527518 Minimum EFLP flow rate in a 24 VDC system Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 254 EFLP and the TPIR are clear. tween the EFLP and the TPIR are not blocked or kinked. Repair: Replace the EFLP. If the fault is still present, contact the Dealer Solutions Network. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 255 E947 (2) 4360-18 operating range. Follow the troubleshooting procedure to identify the root cause of the fault. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 256 If the SCR inlet temperature is abnormal, install a re- placement SCR temperature sensor. Refer to Disassem- bly and Assembly, Temperature Sensor (Exhaust) - Remove and Install (Selective Catalytic Reduction (SCR) Temperature Sensor). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 257 “Service tool Error Identifiers”. Repeat Test Step 3. Result: The “Manual Hydrocarbon Dosing Capability Test” failed. No error identifiers are generated. Contact the Dealer Solutions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 258 This code is a Level 1 inducement associated with an emis- Aftertreatment SCR Operator Inducement E1389 (1) sion activated fault. 5246-15 Severity : High - least severe (1) The Emissions System Malfunction Lamp is on. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 259 Aftertreatment #1 Intake NOx : Not Respond- DEF Quality/Tampering/Dosing Interruption E1431 (2) 3216-7 ing Properly Aftertreatment #1 Intake NOx : Other Failure DEF Quality/Tampering/Dosing Interruption 3216-11 3002-11 Mode (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 260 4334-4 3090-4 solute Pressure : Voltage Below Normal Aftertreatment #1 SCR Dosing Reagent Ab- DEF Quality/Tampering/Dosing Interruption E930 (2) 4334-16 solute Pressure : High - moderate severity (2) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 261 Control Unit Relay : Current Below Normal Aftertreatment #1 Diesel Exhaust Fluid Dos- DEF Quality/Tampering/Dosing Interruption 5965-6 3838-6 ing Control Unit Relay : Current Above Normal Engine Emissions Operator Inducement Service Mode Override Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 262 The engine may be derated by 25% torque. When the DEF tank is empty, the following indications will be present: • The Emissions System Malfunction lamp will flash • The Shutdown lamp will be on Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 263 1761-17 1761-18 1761-1 PDL Code E954 (1) E954 (2) E954 (3) Inducement Trigger Above 20 percent Below 20 percent Below 14 percent Below 8 percent 3.5 Percent reading (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 264 The system must be fault-free for 40 hours before the system resets to zero. If the fault is intermittent and returns within 40 hours, the repeat inducement timings will be triggered. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 265 The system must be fault-free for 40 hours before the system resets to zero. If the fault is intermittent and returns within 40 hours, the repeat inducement timings will be triggered. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 266 Valve Lash Is Excessive Probable Causes • Lubrication • Valve train components Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in order. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 267 · Pushrods · Hydraulic lifters Result: All the valve train components are OK. · Camshaft · Valve stems Contact the Dealer Solutions Network (DSN). · Rocker shafts Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 268 If the total operating hours of the engine are greater than 100, the aftertreatment identification module will cease to send the signal. The diagnostic codes that are listed in Table 147 will be disabled. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 269 6 N·m (53 lb in). Proceed to Test Step 3. E. Check the harness for abrasion and pinch points from the after- treatment identification module back to the ECM. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 270 C. Check the resistance between pin 70 on the P1 connector and terminal 3 on the harness connector for the aftertreatment identifica- Proceed to Test Step 5. tion module. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 271 CAN Data Link - Test Use this procedure if a fault is suspected in the CAN data links. Also, use this procedure if one of the following diagnostic codes is active: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 272 Note: The wiring for a J1939 data link is a shielded twisted-pair cable. If the wiring is damaged, the replacement type must be shielded twisted-pair cable. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 273 Circuit Tests Illustration 93 g03705249 Typical example of the schematic for the CAN A data link Illustration 94 g03705266 Typical example of the schematic for the CAN C data link Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 274 Depending on the application, one or both of the terminating resistors may be located in other ECMs on the data link. Measure the resistance of the two terminating resistors. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 275 Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The other devices are operating correctly. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 276 During the following procedure, refer to the electrical schematic for the application. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 277 Result: The “Coolant Level Sensor” parameter is pro- grammed correctly. C. Verify that the “Coolant Level Sensor” parameter is programmed to “Installed” . Proceed to Test Step 3. D. Remove electrical power from the ECM. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 278 Use this procedure to troubleshoot the electrical system if a problem is suspected with the engine fan control solenoids. Use this procedure if one of the diagnostic codes in Table 152 is active. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 279 During the following procedure, refer to the electrical schematic for the application. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 280 Repair: Replace the engine fan control solenoid. Reset all active codes and clear all logged codes. Verify that D. Restore the electrical power to the ECM. the fault is resolved. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 281 The ECM determines the desired fan speed based on the ATAAC temperature and the coolant temperature. The viscous clutch cooling fan solenoid is controlled by a PWM signal from the ECM. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 282 Repair: Replace the engine fan control solenoid. Reset all active codes and clear all logged codes. Verify that D. Restore the electrical power to the ECM. the fault is resolved. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 283 During the following procedure, refer to the electrical schematic for the application. Table 157 Required Tools Part Description Tool Part Number Tachometer Kit Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 284 Tooling (A). H. Deactivate the “Fan Override Test” . I. Turn the keyswitch to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 285 I. Restore all connectors and wiring to the original configuration. i06163220 Data Link - Test Use this procedure if the electronic service tool will not communicate with the ECM through the data link. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 286 Schematic of the diagnostic connector and the data link connector for a diagnostic connector that is mounted off engine Illustration 96 g03705767 Schematic of the diagnostic connector and the data link connector for an engine mounted diagnostic connector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 287 24 V system. The voltage is not between 11.0 VDC and 13.5 VDC for a 12 V system. The diagnostic connector is not currently receiving the correct voltage. Proceed to Test Step 4. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 288 Illustration 97 g03705906 Typical view of the diagnostic connector from the wire side (A) Switched battery + (B) Battery ground (GND) (D) Data link + (E) Data link - Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 289 C. If another engine is not available, obtain a replacement commu- nications adapter and a replacement set of cables. Ensure that the cables for the electronic service tool are a complete set. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 290 Do not connect the bypass harness to the battery un- til the in-line fuse has been removed from the Battery + line. If the fuse is not removed before connection to the battery, a spark may result. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 291 UENR4469-36 Circuit Tests Illustration 98 g03732687 Schematic of the bypass harness connector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 292 (26) J1939 (CAN) - (28) Data link - (69) Keyswitch (81) Battery ground (GND) (82) Battery ground (GND) (83) Battery ground (GND) (84) Battery + (85) Battery + (86) Battery + Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 293 Use this procedure if one of the following diagnostic codes are active. Note: Some of the following codes may not be applicable for certain applications. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 294 Repair: Obtain the correct flash file and update the C. Check if the personality module code is valid for the application. ECM. Reset all active codes and clear all logged codes. Return the unit to service. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 295 Return the unit to service. B. Select the ECM connection that is related to the logged code. If the procedure did not correct the fault, contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 296 ECM Normal and the DCU. Illustration 100 g06206536 Schematic for the DCU electrical power supply circuit Not all connectors are shown. Refer to the electrical schematic. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 297 Note: Other diagnostic codes will be active with the DCU connector disconnected. Disregard all other codes and only look for diagnostic codes that relate to the DCU keyswitch. E. Turn the keyswitch to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 298 Repair: Replace the wiring between the 31-pin connector and the ECM. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 299 -6 code may be generated for a low current condition. If either code is active for one of the DEF line heaters, follow the troubleshooting for both codes. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 300 Follow the troubleshooting procedure to identify the root cause of the fault. Note: Refer to Troubleshooting, “Component Location” for the locations of the components listed in this procedure. Illustration 101 g03828378 Schematic diagram of the DEF line heater circuit Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 301 D. Use the electronic service tool to override each DEF line heater. E. Verify if any of the diagnostic codes that are listed in Table 166 are active. F. Turn the keyswitch to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 302 Proceed to Test Step 6. turn terminal on the 31-pin connector and the return terminal on the line heater harness connector. Refer to Illustration 101 . E. Reconnect the connectors. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 303 Refer to Disassembly and Assembly for the correct procedure. Result: A -6 diagnostic code is still active with the line heater disconnected. Proceed to Test Step 8. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 304 These codes can be activated only when the DCU is sending a command to the DEF pump. Table 168 lists the diagnostic codes for the DEF pump circuit. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 305 Proceed to Test Step 3. bleshooting, “Electronic Service Tools” B. Establish communication between the electronic service tool and the Dosing Control Unit (DCU). C. Look for active codes. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 306 4334–20 or 4334–21 diagnostic code. parameter. If the diagnostic code is no longer active, return the en- gine to service. If the diagnostic code is still active, proceed to Test Step (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 307 The signal from the DEF pump pressure sensor is below −10 kPa (−1.5 psi) 4334–21 3090–21 sure (absolute) : Data Drifted when the DEF system is not primed. Follow the troubleshooting procedure to identify the root cause of the problem. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 308 4334–20 or 4334–21 diagnostic code. parameter. If the diagnostic code is no longer active, return the engine to service. If the diagnostic code is still active, proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 309 C. Perform the “DEF Dosing Verification Test” . i08787191 DEF Pump Sensor Supply - Test Table 172 lists the diagnostic codes for the Diesel Exhaust Fluid (DEF) pump sensor circuit. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 310 Return the unit to service. engine. Result: The code returned. B. Connect the electronic service tool. Contact the Dealer Solutions Network (DSN). C. Perform the “DEF Dosing Verification Test” . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 311 (CAN C+) and terminal 1 (CAN C-). The ECM provides short circuit protection for the internal power supply. A short circuit to the battery will not damage the internal power supply. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 312 From 2017 onwards, the tank header unit also houses a DEF quality sensor. The sensors are not serviceable individually. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 313 D. Use the electronic service tool to check the DEF level measurement. Proceed to Test Step 4. Note: Use the electronic service tool for this step and not a gauge on the application. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 314 The ECM detects current that is above the Normal acceptable value 3226-5 3609-5 Aftertreatment 1 Outlet NOx : Current Below The ECM detects current that is below the ac- Normal ceptable value (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 315 The ECM detects voltage that is outside the Power Supply: Other Failure Mode acceptable value. The engine ECM requires the keyswitch to be in the ON position to maintain communications with the electronic service tool. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 316 UENR4469-36 Circuit Tests Illustration 104 g03813883 Schematic diagram for the engine electrical power supply circuit Not all connectors are shown. Refer to the appropriate electrical schematic Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 317 Schematic for the NOx sensor power supply circuit Not all connectors are shown. Refer to the appropriate electrical schematic Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 318 Repair: There is a fault in the charging system. Make the necessary repairs. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 319 Activation of the ether starting aid is based from a map using the coolant temperature, intake manifold temperature, and atmospheric pressure. Refer to Illustration 107 . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 320 To re-enable Ether injection, a successful start must be achieved, the engine run at low idle speed for at least 5 seconds and a minimum SCR inlet temperature of 160°C achieved for at least 5 seconds. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 321 Schematic for the ether injection system Not all connectors are shown. Refer to the appropriate electrical schematic. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 322 Result: The measured resistance was not approximately 20 Ω. B. Measure the resistance of the coil inside the ether control. Repair: Replace the ether control. Proceed to Test Step 4. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 323 Use this procedure to troubleshoot the relay for the Electric Fuel Lift Pump (EFLP). Use this procedure if there is a suspected electrical fault with the EFLP. This procedure covers the following diagnostic codes: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 324 When the keyswitch is turned to the ON position, the ECM will activate the EFLP. If the engine is not running, the ECM will deactivate the EFLP after 2 minutes. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 325 UENR4469-36 Circuit Tests Illustration 112 g03813928 Schematic for the Electric Fuel Lift Pump (EFLP) relay Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 326 There may be a fault with codes. the switched power circuit for the EFLP. The ECM does not monitor the status of this condition. Proceed to Test Step 7. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 327 6 or 3666-6 diagnostic code. Result: A 1075-6 or 3666-6 diagnostic code is still active. E. Turn the keyswitch to the OFF position. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 328 EFLP. Result: Battery voltage is present at the EFLP harness connector. If the EFLP does not activate when the keyswitch is turned to the ON position, replace the EFLP. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 329 ON: “ “ Wait to Start Lamp” ” • Coolant temperature This feature may be included as an option. • Intake manifold air temperature Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 330 Illustration 113 g03815124 Schematic for the glow plug starting aid circuit Not all connectors are shown. Refer to the appropriate Electrical Schematic. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 331 Table 183 . cently logged. Proceed to Test Step 3. Result: Diagnostic code 676-6 or 2246-6 is active or re- cently logged. Proceed to Test Step 5. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 332 D. Use the electronic service tool to check for active diagnostic Proceed to Test Step 6. codes. Wait at least 30 seconds for activation of the diagnostic codes. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 333 Refer to the appropriate Electrical appropriate Electrical Schematic. Schematic. Make any necessary repairs. Replace the blown fuse. Result: The fuse is not blown. Proceed to Test Step 10. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 334 • The engine will default to limp home mode. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 335 • If necessary, reset the IVS threshold for an existing IVS. • If necessary, view the IVS change point and reset the IVS thresholds when a new throttle assembly is installed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 336 UENR4469-36 Circuit Tests Illustration 114 g03712853 Schematic of the IVS circuit Not all connectors are shown. Refer to the appropriate Electrical Schematic Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 337 Select “Status” function and then select “Throttles” function. G. The throttle is set in the low idle position. H. Operate the throttle slowly. The IVS status should change from CLOSED (ON) to OPEN (OFF). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 338 6 N·m (53 lb in). Proceed to Test Step 5. D. Check the harness for abrasion and pinch points from the throttle switch to the ECM. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 339 Result: All resistance measurements are greater than 1 k Ohm. E. Use a multimeter to check the resistance between P1:36 and all other terminals on the P1 connector. Contact the Dealer Solutions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 340 Return the engine to service. Note: The limits are shown in the “Throttle Configuration” screen which is located in the “Service” menu. Result: The fault is not cleared. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 341 ON and OFF. Note: The diagnostic aid that switches the lamps is contained in the “Override” section in the “diagnostics” menu of the electronic service tool. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 342 B. Measure the resistance across the two terminals of the nates the fault. lamp. Result: The lamp has less than 2000 Ohms resistance. Proceed to Test Step 3. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 343 Engine Injector Cylinder #01 : Erratic, Intermittent or The Electronic Control Module (ECM) detects an injec- Incorrect tor code that is incorrect for the engine. The warning lamp will come on. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 344 Refer to Troubleshooting, “Injector Code - Calibrate” for further information. Illustration 117 g02132293 Sequence for recording the injector code Illustration 116 g02131289 Typical code plate on an injector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 345 If the procedure did not correct the issue, contact the Deal- er Solutions Network (DSN). i06165243 Injector Solenoid - Test This procedure covers the following diagnostic codes: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 346 An open or short circuit in common wiring within the ECM can prevent the two electronic unit injectors that share that common wiring from operating. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 347 UENR4469-36 Circuit Tests Illustration 118 g03713296 Schematic of the circuit for the injector solenoids Illustration 119 g02041293 Fuel injector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 348 Do not come in contact with the harness connector for the elec- tronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 349 The “Injector Solenoid Test” is used to actuate the injector sol- enoids while the engine is not running. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 350 D. Perform the “Injector Solenoid Test” at least two times. E. Repeat this test for each suspect injector. Stop the “Injector Solenoid Test” before handling the jumper wires. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 351 C. Thoroughly inspect the P2 connector. Refer to Trouble- Result: All resistance measurements are greater than 1 k shooting, “Electrical Connectors - Inspect”. Ohm. Contact the Dealer Solutions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 352 Each mode also has a specific droop value for throttle 1 and throttle 2. Table 193 Mode Switch 2 Switch 1 Enabled Number Open Open Open Closed Closed Open Closed Closed Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 353 D. Monitor the status screen on the electronic service tool. Proceed to Test Step 3. Cycle the mode switch to the ON position and to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 354 Ohms. There is a fault in the ECM. E. Use a multimeter to measure the resistance between P1:78 Contact the Dealer Solutions Network (DSN). and all other terminals on the P1 connector. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 355 168 diagnostic codes are not active. The ECM has been powered for at least 2 seconds. If equipped, the warning lamp will come on. The ECM will log the diagnostic code. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 356 As the soot level in the DPF reduces, the ECM commands the EBPR to open, reducing the exhaust back pressure to a normal level. The EBPR is also used on engines with no DPF to control deposit management. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 357 UENR4469-36 Circuit Tests Illustration 123 g03732809 Schematic for the motorized valves Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 358 Result: No diagnostic codes are active or logged. Repair: For intermittent faults, refer to Troubleshooting, “Electrical Connectors - Inspect”. If no intermittent faults are found, return the unit to service. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 359 Result: A -5 diagnostic code is still active with the jumper installed. Proceed to Test Step 5. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 360 E. For the NRS valve, use a multimeter to check the resist- ance between P2:4 and all other terminals on the P2 If the fault has not been eliminated, contact the Dealer Sol- connector. utions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 361 E1410 (2) 4364-2 Camera E946 (2) 4360-16 E947 (1) 4360-17 E947 (2) 4360-18 E2165 (1) 4765-17 5298-17 2180-1 Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 362 Proceed to Test Step 5 Result: Droplets do not form around the DEF injector noz- zle during the prime pressurization phase of the test. Proceed to Test Step 5 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 363 UENR4469-36 Circuit Tests Illustration 124 g06305048 Typical example of droplets forming on the DEF injector nozzle Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 364 SCR inlet temperature rise above 450° C (842° F). Result: The Clean Emissions Module (CEM) Mixer As- sembly contains no DEF deposits. Refer to Illustration 126 (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 365 Illustration 125 g06304951 Typical example of DEF deposits in the CEM mixer assembly Illustration 126 g06305355 Typical example of a CEM mixer assembly with DEF deposits cleared Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 366 - Remove and Install” for the correct procedure. Proceed to Test Step 12. Result: There were exhaust leaks found. Repair: Repair the exhaust leaks. Proceed to Test Step 13. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 367 The PTO switches provide the operator with the ability to select the desired engine speed. Engine speed will decrease with increasing load. The PTO switches can be used to control the engine speed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 368 UENR4469-36 Circuit Tests Illustration 127 g03733170 Schematic for the PTO switches Not all connectors are shown. Refer to the appropriate Electrical Schematic. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 369 Result: The PTO mode - Disengage switch does not op- by the operation of the brake, clutch, or the operator switch. erate correctly. These switches should be operated separately for this test. Proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 370 The ECM detects a high current condition in the aftertreatment Aftertreatment #1 DEF Control Module Relay 5965-6 3838-6 power relay circuit. Control : Current Above Normal Follow the troubleshooting procedure to identify the root cause of the fault. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 371 Result: Diagnostic code 5965-6 or 3838-6 is active or re- Note: Do not start the engine. cently logged. C. Use the electronic service tool to check for active diagnos- Proceed to Test Step 5. tic codes. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 372 Contact the Dealer Solutions Network (DSN). ness connector for the aftertreatment power relay and P1:5. E. Measure the resistance between Terminal 86 on the har- ness connector for the start relay and P1:15. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 373 Table 206 is active or easily repeated. Table 206 Diagnostic Codes Table for Sensor Calibration Code Description J1939 Code PDL Code Comments (code descriptions may vary) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 374 Pressure : Out of Calibration during sensor calibration with the engine not running. The warning lamp will come on and the engine will derate. The code is logged. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 375 3. Check the Barometric Pressure Sensor Barometric pressure Result: There is no active -13 code. The fault was sensor fault caused by a faulty barometric pressure sensor. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 376 D. Monitor the status parameter for the suspect sensor on the electronic service tool. Illustration 129 g03724216 (1) Pipe for the NRS differential pressure (2) Pipe for the NRS inlet pressure sensor sensor Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 377 Use this procedure to troubleshoot the electrical system if a fault is suspected with the CAN data link sensors. Also use this procedure if a diagnostic code in Table 209 is active or easily repeated. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 378 • The flash file in the ECM is newer than the version of the electronic service tool. • The latest version of the electronic service tool has not been installed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 379 Schematic for the data-type sensors Not all connectors are shown. Refer to the appropriate Electrical Schematic. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 380 Note: Do not use abrasive materials or fluids to clean the NOx sensor. Reinstall the NOx sensor. Refer to Disassembly and As- sembly for the correct procedure. Proceed to Test Step 8. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 381 E. Check for active diagnostic codes. If the fault is still present, proceed to Test Step 7. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 382 The ECM detects signal voltage that is not in the acceptable range. Voltage Below Normal The code is logged. The value of the parameter is set to a gauge pressure. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 383 The following conditions must exist before any of the • There are no active 168 codes. above codes will become active: The following background information is related to this procedure: • There are no active 3509 codes. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 384 If the sensor is disconnected and the voltage is different from pull-up voltage, the signal wire is shorted to another wire in the harness. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 385 UENR4469-36 Circuit Tests Illustration 131 g06274072 Schematic for the active sensors Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 386 Fuel rail pressure sensor (1) Ground (2) Signal (3) 5 VDC Supply Illustration 133 g01170310 Typical example of an engine pressure sensor (1) 5 VDC Supply (2) Ground (3) Signal Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 387 Result: The supply voltage is not approximately 5.0 ± 0.2 VDC. There is a short in the harness to the battery. Repair the wiring or replace the harness Verify that the problem is resolved. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 388 Refer to Disassembly and Assembly, Pressure Sensor (Cooled Exhaust Gas) - Remove and Install. Verify that the problem is resolved. If the fault is still present, contact the Dealer Solutions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 389 3. Insert a pin into each socket. Verify that each socket grips the pin firmly. Repair any problems. 4. Connect all connectors. 5. Verify that the problem is resolved. 6. Return the unit to service. STOP Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 390 Above Normal” will be displayed next to the status for “Engine Coolant Temperature” on the electronic service tool. The engine may show the following symptoms: Poor stability Poor cold running White smoke (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 391 Engine Exhaust Gas Recircula- 412-4 3386-4 tion Temperature : Voltage Be- The signal voltage from the NRS temperature sensor is less than 0.2 VDC for low Normal more than 8 seconds. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 392 7 minutes. “Voltage Above Normal” will be displayed next to the status for “SCR Inlet Temperature” on the electronic service tool. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 393 “Voltage Below Normal” will be displayed next to the status for “Aftertreatment Ambient Air Temperature” on the electronic service tool. Follow the troubleshooting procedure in order to identify the root cause of the fault. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 394 When the ECM/DCU detects a voltage above a threshold on a signal circuit, an open circuit diagnostic code (XXX-3) is communicated to the engine ECM. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 395 Schematic for passive engine temperature sensors on the P1 connector Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 135 g03675493 Schematic for passive engine temperature sensors on the P2 connector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 396 Typical view of an engine temperature sensor (1) Signal (2) Ground Illustration 137 g03714041 Typical view of a CEM temperature sensor and mating connector (1) Signal (2) Ground Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 397 Wait at least 30 seconds in order for the diagnostic codes rently active, Proceed to Test Step 4. to become active. D. Look for one of the diagnostic codes that are listed in Table 213 . (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 398 E. Turn the keyswitch to the OFF position. Repair: Replace the faulty sensor. Result: No error codes are active in the new position. Verify that the problem is resolved. For other passive sensors: (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 399 The engine may be limited to low idle. An active diagnostic code may not cause any noticeable effect on engine response unless the voltage drops below 6.5 VDC. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 400 • NRS valve position sensor • Exhaust Back Pressure Regulator (EBPR) position sensor A diagnostic code can be caused by the following conditions: • A short circuit in the harness Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 401 Note: Refer to the Electrical Schematic for the application for information regarding components that are connected to the 5 V and 8 V supplies on the J1/ P1 connector. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 402 Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Proceed to Test Step 2. B. Turn the keyswitch to the ON position. C. Determine if a diagnostic trouble code is present. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 403 Aftertreatment #1 DEF Dosing 3361-6 3821-6 Unit : Current Above Normal There are no active 168 diagnostic codes. The warning lamp will come on. The diagnostic code will be logged. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 404 This override allows the user to test the electrical circuit for the DEF injector. The override commands the DEF injector to open. This override only operates when there is no engine speed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 405 Illustration 144 g03733173 Schematic for the solenoid valves Not all connectors are shown. Refer to the appropriate Electrical Schematic. Illustration 145 g03714645 Illustration 146 g03714646 Coolant diverter valve DEF injector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 406 Diverter Valve Solenoid Override” . H. Verify if any of the diagnostic codes that are listed in Table 217 are active. I. Turn the keyswitch to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 407 D. Use a multimeter to check the resistance between the re- turn terminal on the 31-pin connector and the return terminal on the component connector. Refer to Illustration 144 . E. Reconnect the connectors. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 408 31-pin connector and all other terminals in Contact the Dealer Solutions Network (DSN). the 31-pin connector. Check the resistance between the return terminal on the 31-pin connector and a known good ground. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 409 “Turbo Pro- tection Derate Active” . This diagnostic code detects a fault in the wastegate regulator that is most likely to be an open circuit. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 410 The amount of fuel that is required is calculated by the software that is contained in the ECM. The solenoid in the suction control valve is controlled by a PWM signal from the ECM. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 411 Schematic for the solenoid valves Illustration 148 g03714641 Illustration 149 g03714642 Typical example of the high-pressure fuel pump (1) Wastegate regulator (2) Solenoid for the Suction Control Valve (SCV) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 412 D. Verify if any of the diagnostic codes that are listed in Table 219 are active. E. Turn the keyswitch to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 413 D. Use a multimeter to check the resistance between the re- turn terminal on P2 and the return terminal on the valve Contact the Dealer Solutions Network (DSN). connector. Refer to Illustration 147 . E. Reconnect the connectors. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 414 Use this procedure to troubleshoot a fault with the soot sensor. Also, use this procedure if the diagnostic code in Table 221 is active or easily repeated. Table 221 Diagnostic Codes Table for Soot Sensor (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 415 Diesel Particulate Filter (DPF). The soot sensor calculates the soot load in the DPF by measuring the attenuation of the signal. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 416 View of the pin locations on the P1 connector for the soot sensor (17) CAN C + (18) CAN C - Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 417 C. Turn the keyswitch to the OFF position. Repair: Investigate the cause of the high voltage. Refer to Systems Operation, Testing and Adjusting, “Charging System - Inspect”. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 418 · “Diagnostic Tests” · “DPF Soot Loading Sensor Functional Test” If the fault has not been eliminated, contact the Dealer Solutions Network (DSN). H. Disconnect the coaxial cables from the attenuator. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 419 The diagnostic codes above relate to an analog speed, the engine will decelerate to the limp home sensor. Use this procedure only if the analog sensor speed. uses an output from a variable resistor. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 420 During the following procedure, refer to the electrical schematic for the application. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 421 C. Observe the throttle position reading on the electronic serv- ice tool. Result: The sensor is operating correctly. D. Operate the throttle over the full range of movement. Proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 422 Proceed to Test Step 9. codes. Result: There are no active diagnostic codes for the throttle position sensors - The fault may be intermittent. Repair: Refer to Troubleshooting, “Electrical Connector - Inspect”. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 423 P1 connector. fault. Result: The resistance measurement is less than two Ohms. Contact the Dealer Solutions Network (DSN). (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 424 Contact the Dealer Solutions Network (DSN). i06167057 Speed Control - Test (PWM) Use this procedure if the digital throttle position sensor is suspected of incorrect operation. This procedure also covers the following diagnostic codes: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 425 Normal The setting for the upper diagnostic limit has been exceeded for one second. If equipped, the warning lamp will come on. The diagnostic code will be logged. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 426 +8 VDC from the ECM. The supply voltage is from • All inputs from the faulty throttle are ignored by the J1: to the digital throttle position sensor connector. ECM until the fault is repaired. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 427 During the following procedure, refer to the electrical schematic for the application. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 428 This process is done to en- sure that the throttle reaches these two critical points for en- gine operation. E. Turn the keyswitch to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 429 D. Measure the voltage between the +8 VDC terminal and the sensor return terminal. Result: The sensor supply voltage is within the expected range. Proceed to Test Step 5. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 430 · “Service” · “Throttle Configuration” · “Throttle# 1” F. Make a note of the lower diagnostic limit and the upper diag- nostic limit. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 431 The warning lamp will come on and the diagnostic code will be logged. The loss of signal from the secondary speed/timing sensor will prevent the engine from starting. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 432 Use this procedure when the engine will not start and the electronic service tool indicates a faulty sensor by displaying “Not Detected” against the faulty sensor on the “No Start Parameter” screen. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 433 • The engine will continue to run when only one sensor signal is present from either the primary sensor or the secondary sensor. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 434 (18) Supply for the speed/timing sensor (8 VDC) (27) Signal for the primary speed/timing sensor (28) Signal for the secondary speed/timing sensor Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 435 B. Turn the keyswitch to the ON position. If the engine will run, then run the engine. C. Use the electronic service tool to check if the 637-11 or 261-11 diagnostic code is still active. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 436 D. Measure the voltage from terminal 1 on the sensor connec- fault. tor to engine ground. Result: The sensor supply voltage is correct. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 437 Refer to Illustration 156 . fault. Result: All resistance measurements are greater than 100 Ohms. Proceed to Test Step 9. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 438 If equipped, the warning light will come on. The ECM will log the diagnostic code. Follow the troubleshooting procedure in order to identify the root cause of the fault. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 439 The voltage should be less than 0.5 VDC when the throttle inputs are closed. During the following procedure, refer to the electrical schematic for the application. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 440 Result: The fault is not in the throttle switch. tle input. Proceed to Test Step 4. D. Observe the status of the suspect throttle input on the elec- tronic service tool. E. Remove the jumper wire. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 441 Table 232 . Table 232 Diagnostic Trouble Codes for the Air Filter Restriction Switch Code Description J1939 PDL Code Comments (Code descriptions may vary) Code (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 442 Refer to Troubleshooting, “Inlet Air Is Restricted”. During the following procedure, refer to the electrical schematic for the application. Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 443 The warning lamp will come on. The ECM will log the diagnos- tic code. The NRS valve will be fully closed while the code is active. The engine will be derated. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 444 A short circuit to the battery will not damage the circuit inside the ECM. The signal voltage from terminal “3” of both valves is supplied to the appropriate terminal at the P2 ECM connector. Pull-up Voltage Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 445 Pin locations on the P2 connector for the valve position sensors (1) Valve position sensor 5 VDC supply (10) Valve position sensors ground (30) Combustion air valve position sensor signal (38) NRS valve position sensor signal Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 446 Connector for the exhaust back pressure regulator (1) 5 VDC supply (2) Position sensor ground (3) Position sensor signal Complete the procedure in the order in which the steps are listed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 447 E. Reconnect the valve to the harness. Result: The sensor supply voltage is correct. Proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 448 Result: There is still an XXXX-4 diagnostic code active with the signal wire removed. The valve position sensor is OK. Repair: Return all wires to the original configuration. Proceed to Test Step 6. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 449 Result: The measured resistance is less than two resistance between terminal 3 on the valve connector and Ohms. P2:30. Contact the Dealer Solutions Network (DSN). E. Install the removed connectors. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 450 WIF sensor will close for 5 seconds. If the ECM does not detect a signal from the WIF sensor during this period, a 97–3 (3547-3) diagnostic code will become active. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 451 WIF sensor. Reconnect the WIF sensor to the harness. Proceed to Test Step 4. E. Turn the keyswitch to the OFF position. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 452 Result: The measured resistance is less than 2 Ohms. the correct terminals. There may be a short circuit in the harness. Proceed to Test Step 7. D. Install the removed connectors. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 453 Result: The measured resistance is greater than 100 Ohms. There is a fault in the ECM. D. Reconnect the WIF sensor to the harness. Reconnect the P1 connector. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 454 The reset ensures that the DCU completes a purge cycle, resets any active codes, and shuts down Unless the function is disabled, the override will correctly. remain enabled for 5 minutes. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 455 Select the “Logged Diagnostic Codes” tab. other functions in the electronic service tool. Factory passwords are required to perform this override as the engine will be operating outside of the emissions window. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 456 There are no test results if the “Change” button is selected to power or cutout an individual injector. When selected, the “Power All” and “Cutout All” buttons do not give test results. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 457 This test is used to determine if the mean soot level is • No related active diagnostic codes within range. • Coolant at the minimum required temperature • Engine speed and load in the required range Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 458 • Exhaust gas at the minimum required temperature • Sufficient DEF in the tank • No related active diagnostic codes • Engine speed and load in the required range Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 459 This test primes the dosing system to the required pressure for dosing. The test checks that the DEF pump is able to build adequate pressure and ensure that there are no leaks in the system. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 460 • No related active diagnostic codes Select the “Service” tab. Select the “Dyno Mode” tab. • Coolant temperature condition met • Engine speed and load in the required range Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 461 Note: This test is only applicable to engines that time to remove sulfur and/or urea deposits from the have a DPF in the aftertreatment system. SCR catalyst. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 462 A hot shutdown can damage the aftertreatment or SCR system. This test must be performed under the following conditions: A cold shutdown can damage the SCR dosing system. • There are no related active diagnostic codes Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 463 9.5 seconds before and 3.5 seconds after the time a diagnostic trouble code was recorded. 1. Select the “Information” tab. Select the “Snapshot” tab and then select the “Viewer” tab. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 464 UENR4469-36 Service Illustration 161 g03826867 2. Select the diagnostic trouble code to be viewed. Select “View Data” . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 465 UENR4469-36 Service Illustration 162 g03738281 3. Select a group or select “Temporary Group” Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 466 UENR4469-36 Service Illustration 163 g03826868 4. Select the channels to view and add the channels to the group. Select “OK” . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 467 5. The sliding time bar indicates when the diagnostic trouble code was recorded. Data can be viewed 9.5 seconds before and 3.5 seconds after the time the code was recorded. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 468 UENR4469-36 Service Illustration 165 g03826871 6. Select the “View Graph” tab for graphic illustrations. Select the channels to be viewed and then select “OK” . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 469 This function labels all bars in the graph. View Labels on Mouseover This function labels each bar in the graph as the mouse pointer is moved over the bar. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 470 UENR4469-36 Service Screen Shots Illustration 167 g03826874 Illustration 168 g03826876 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 471 UENR4469-36 Service The amount of engine hours operated at indicated inlet temperature. Illustration 169 g03826877 The amount of engine hours operated at indicated coolant temperature. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 472 Service Illustration 170 g03826880 The amount of engine hours operated at indicated engine speed. Illustration 171 g03826881 The amount of engine hours operated at indicated intake manifold air temperature. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 473 UENR4469-36 Service Illustration 172 g03826883 The amount of engine hours operated at indicated intake manifold pressure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 474 This screen is used to illustrate load percentage at the current engine speed. This screen can be helpful in understanding how the engine is being used. The screen can also be used for comparison between similar machines and/or operators. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 475 “DPF#1 Soot Loading Percent” will also reset. The reset must be performed only when a new clean DPF is being fitted. Note: A factory password is required to perform this reset. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 476 The “Operator Inducement Emergency Override Timer” can then be reset to allow reactivation if a subsequent emergency situation arises. Note: A factory password is required to perform this reset. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 477 The permitted throttle combinations are shown in the following table: Table 239 Channel 1 Channel 2 None None None None (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 478 Programming each throttle input requires some technical knowledge of the throttle specification that is being used. Knowledge is required to program the specifications into the correct ECM parameter values. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 479 UENR4469-36 Service Illustration 177 g03826890 Screen 1 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 480 UENR4469-36 Service Illustration 178 g03826896 Screen 2 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 481 UENR4469-36 Service Illustration 179 g03826897 Screen 3 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 482 Mode 1 and Mode 2. If three or four modes are required, two switch inputs will be required. The numbers of switches are selected in the drop-down box at the top of the screen. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 483 • TSC1 Droop Value – This parameter is configurable between 0-10%. • Governor Type – This parameter can be configured to “All Speed” governing or “Min Max” governing using the drop-down box. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 484 (240 hours). The standard mode strategy can be used multiple times until the standard mode timer is expired or engine run backstop timer has been reached. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 485 DEF lines, with an arctic package. The purpose is to provide a more accurate temperature to be used for DEF thawing control. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 486 Incorrect Throttle Position may be faulty. $101B Shift Lever Not in Neutral Shift the transmission lever to NEUTRAL. Shift the power train to NEUTRAL. $101C Transmission Gear Incorrect (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 487 Engine speed must be higher than or equal to Engine Speed Too Low $10FB low idle speed. Engine speed must be lower than or equal to Engine Speed Too High $10FC rated speed. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 488 Follow the troubleshooting procedure for the Fuel Leakage Detected $1162 fuel leakage event. Refer to Troubleshooting, “Fuel Rail Pressure $1101 Fuel Rail Pressure Too Low Problem”. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 489 Restart the Aftertreatment Regeneration Sys- Service Test Aborted by ECM $0009 tem Test. Engine Stopped (No Engine RPM) Start the engine. Test will then progress. $1010 (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 490 Engine Exhaust Gas Recirculation Valve Not cally OK, but the actuator is not responding to $116F Responding to Command the desired test profile. Contact the Dealer Solutions Network (DSN) before proceeding. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 491 NH3 storage. The temperature of the DEF is too low. Oper- Aftertreatment Diesel Exhaust Fluid Tempera- $11AA ate the engine to raise the DEF Temperature. ture Too Low (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 492 HC dosing Aftertreatment Diesel Oxidation Catalyst Con- $11CA fuel being injected. The DOC may be sulfated. version Efficiency Too Low Run the “Aftertreatment Recovery Procedure” (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 493 Temperature Too Low haust gas reaches the SCR. Check for signs of exhaust leaks in the CEM between the DOC and the SCR. High Pressure Fuel Pump Calibration (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 494 Changing the engine operating condition may allow successful pump learn. A lower engine Engine Load Incorrect $115F speed and/or a lower load condition should be used. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 495 Lower the engine speed to idle. The test will try to take speed control to put engine in ac- Engine RPM Too High $10FC ceptable speed range. Restart the Aftertreat- ment Recovery Procedure. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 496 Start the engine. Test will then progress. $1010 Lower the engine speed to idle. Test will try to Engine RPM Too Low take speed control to put engine in acceptable $10FB speed range. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 497 Manual DPF Regeneration Proce- Engine Speed / Load Incorrect $1164 dure. The test will try to take control of engine speed to elevate idle to required position for duration of test. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 498 DPF desulfation. Refer to Trouble- shooting, “Diesel Particulate Filter Intake Tem- Particulate Filter Intake Temperature Too Low $112C perature Is Low” and check for exhaust leaks. Restart the Aftertreatment Sulfation Recovery Procedure. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 499 ECM. temporary passwords. Rerate Engine Power – Changing the interlock code may be necessary. The interlock code is protected by factory passwords. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 500 Do not use information • Incorrect configuration of the electronic service from an old ECM in order to program factory tool passwords on a replacement ECM. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 501 • A fault in the electrical power to the engine ECM • A fault in the wiring for a data link • A fault in the electrical cables between the PC and the machine Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 502 However, the “Power” indicator is not illuminated. Proceed to Test Step 5. Result: A correct communication adapter is being used. The “Power” indicator is illuminated. Proceed to Test Step 4. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 503 A “limited support” warning should not be displayed. The “J1939 / Device- Net” and “PDL” indicators should be flashing. The indicator indicates that the electronic service tool is communicating on both data links. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 504 P1 ECM connector. Result: Battery voltage is present at all of the appropriate P1 terminals. Contact the Dealer Solutions Network (DSN). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 505 651-2 Cycle key OFF for 2 minutes, then turn key ON Circuit Check (Auto) 651-5 Cycle key OFF for 2 minutes, then turn key ON Circuit Check (Auto) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 506 Cycle key OFF for 2 minutes, then turn key ON Circuit Check (Auto) 4765-17 E2165 (1) Cycle key OFF for 2 minutes, then turn key ON Circuit Check (Auto) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 507 ECM to the engine. Do not mount the test Note: The “Test ECM Mode” must be activated ECM on the engine. before the engine serial number is programmed into the ECM. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 508 Select the engine ECM under the “Detected Note: The engine serial number must be available in ECMs” . order to search for the part number of the flash file. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 509 ECM. The flash programming transfers Flash Programming a Flash File the flash file from the PC to the ECM. 1. Obtain the part number for the new flash file. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 510 Turn the keyswitch to the OFF position. Wait for at least 2 minutes for the application to fully power down. g. Turn the keyswitch to the ON position. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 511 PTMI data. fault is resolved. 4. Remove power from the ECM. 5. Remove the ECM. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install”. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 512 Do not connect any electrical equipment or disconnect any electrical equip- ment in an explosive atmosphere. Illustration 187 g01131019 Seal for a three-pin connector (typical example) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 513 UENR4469-36 Service Illustration 188 g03137420 (1) Seal for ECM connector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 514 Pull back the harness sleeves to check for a flat- tened portion of wire. A fastener that has been overtightened flat- tens the harness. This condition damages the wires that are inside the harness. (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 515 Result: The terminals are OK. located in the connector. Proceed to Test Step 4. Illustration 189 g01802454 A typical example of the lock wedge. (1) Lock wedge Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 516 If an intermittent fault exists, the status will be highlighted and an audible beep will be heard. Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 517 Select the two electronic unit injectors that will be exchanged and The injector codes must be loaded into the ECM if press the “OK” button. any of the following conditions occur: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 518 The warning lamp will continue to be illuminated until the override is reset. The override may be reset at any point after the initial activation. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 519 UENR4469-36 Service Illustration 192 g06241919 Illustration 193 g06241920 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 520 Return the unit to service. B. Under the “Service Tab” , navigate to “Operator Inducement Emergency Override Timer Reset” . C. Click the “Reset” button at the bottom of the screen. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 521 Draining............92 Electrical Power Supply - Test ......314 Probable Causes ..........92 Electronic Service Tool Does Not Communicate .. 500 Recommended Actions ........92 Electronic Service Tools.........7 Customer Passwords ........499 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 522 Recommended Actions ........234 Factory Passwords..........499 Oil Contains Coolant ......... 237 Fuel Consumption Is Excessive......186 Probable Causes ........... 237 Probable Causes ........... 186 Recommended Actions ........237 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 523 Reset ............476 Override Parameters........454 Service Procedures........460 Service Tool Error Identifiers ......462 System Communication Status ....... 475 System Troubleshooting Settings ....455 Throttle Mode Configuration ......477 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 524 UENR4469 ©2022 Perkins Engines Company Limited All Rights Reserved March 2022 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

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