Perkins Engine 1104 Service Manual

Perkins 1104 Series

WORKSHOP MANUAL Troubleshooting

4 cylinder , naturally aspirated, and turbocharged diesel engines for agricultural and industrial use

Publication RENR2696-00 © Proprietary information of Perkins Engines Company Limited 2004, all rights reserved. The information is correct at the time of print. Published by Technical Publications. Perkins Engines Company Limited, Peterborough, PE1 5NA, England

Table of Contents

Troubleshooting Section

Electronic Troubleshooting

System Overview .................................................... 5

Glossary ................................................................. 9

Electronic Service Tools ........................................ 12

Diagnostic Codes .................................................. 13

Indicator Lamps .................................................... 15

Replacing the ECM ............................................... 18

Self-Diagnostics .................................................... 19

Sensors and Electrical Connectors ....................... 20

Engine Wiring Information .................................... 26

Programming Parameters

Programming Parameters ..................................... 30

Factory Passwords ................................................ 30

Flash Programming .............................................. 30

System Configuration Parameters

System Configuration Parameters ........................ 32

Troubleshooting without a Diagnostic Code

Alternator Noise (Noisy Operation) ....................... 33

Alternator Will Not Charge (Charging Problem) .... 33

Battery .................................................................. 33

Can Not Reach Top Engine RPM ......................... 34

Coolant in Engine Oil ............................................ 36

Coolant Temperature Is Too High ......................... 37

ECM Will Not Accept Factory Passwords ............. 38

ECM Will Not Communicate with Other Systems or

Display Modules .................................................. 38

Electronic Service Tool Will Not Communicate with

ECM .................................................................... 38

Engine Cranks but Will Not Start .......................... 39

Engine Has Early Wear ........................................ 41

Engine Misfires, Runs Rough or Is Unstable ........ 41

Engine Oil in Cooling System ............................... 43

Engine Speed Does Not Change .......................... 44

Engine Stalls at Low RPM .................................... 45

Engine Vibration ................................................... 45

Engine Will Not Crank ........................................... 47

Excessive Black Smoke ........................................ 48

Excessive Engine Oil Consumption ...................... 49

Excessive Valve Lash ........................................... 50

Excessive White Smoke ....................................... 51

Intake Air Temperature Is Too High ....................... 52

Intermittent Engine Shutdown ............................... 53

Intermittent Low Power or Power Cutout ............... 54

Low Engine Oil Pressure ...................................... 56

Low Power/Poor or No Response to Throttle ........ 57

Mechanical Noise (Knock) in Engine .................... 59

Noise Coming from Cylinder ................................. 59

Poor Acceleration or Response ............................ 60

Troubleshooting with a Diagnostic Code

CID 0041 FMI 03 8v Sensor Power Supply, Voltage

More Than Normal .............................................. 62

CID 0041 FMI 04 8v Sensor Power Supply, Voltage

Less Than Normal ............................................... 62

CID 0091 FMI 02 Throttle Demand Sensor Erratic Or

Intermittent .......................................................... 62

CID 0091 FMI 03 Throttle Demand Sensor Open

Circuit Or Shorted High ....................................... 63

CID 0091 FMI 04 Throttle Demand Sensor Shorted

Low ..................................................................... 63

CID 0091 FMI 08 Throttle Demand Sensor Abnormal

Signal .................................................................. 64

CID 0091 FMI 12 Throttle Demand Sensor Out Of

Calibration ........................................................... 64

CID 0100 FMI 03 Engine Oil Pressure Sensor Open

Circuit Or Shorted High ....................................... 64

CID 0100 FMI 04 Engine Oil Pressure Sensor

Shorted Low ........................................................ 65

CID 0100 FMI 10 Engine Oil Pressure Sensor, Power

Supply Open Circuit ............................................ 65

CID 0102 FMI 03 Intake Manifold Pressure Sensor,

Open Circuit Or Shorted High ............................. 66

CID 0102 FMI 04 Intake Manifold Pressure Sensor

Shorted Low ........................................................ 66

CID 0102 FMI 10 Intake Manifold Pressure Sensor

Power Supply Open Circuit ................................. 67

CID 0105 FMI 03 Intake Manifold Temperature

Sensor Open Circuit Or Shorted High ................ 67

CID 0105 FMI 04 Intake Manifold Temperature

Sensor Shorted Low ........................................... 67

CID 0110 FMI 03 Engine Coolant Temperature

Sensor Open Circuit Or Shorted High ................ 68

CID 0110 FMI 04 Engine Coolant Temperature

Sensor Shorted Low ........................................... 68

CID 0174 FMI 02 Fuel Temperature Sensor Erratic,

Intermittent .......................................................... 69

CID 0247 FMI 09 J1939 Datalink, Abnormal

Update ................................................................ 69

CID 0253 FMI 02 Incorrect ECM Software ........... 69

CID 0262 FMI 03 5v Sensor Power Supply, Voltage

More Than Normal .............................................. 70

CID 0262 FMI 04 5v Sensor Power Supply, Voltage

Less Than Normal ............................................... 70

CID 0266 FMI 02 Incorrect Crank-without-inject

inputs .................................................................. 71

CID 0320 FMI 02 Speed And Timing Sensor

Intermittent Loss Of Signal .................................. 71

CID 0320 FMI 11 Speed And Timing Sensor Loss Of

Signal .................................................................. 71

CID 0342 FMI 02 Speed And Timing Sensor No.2

Intermittent Signal ............................................... 72

CID 0774 FMI 02 Throttle Demand Sensor No.2

Erratic Or Intermittent .......................................... 72

CID 0774 FMI 03 Throttle Demand Sensor No.2

Open Circuit Or Shorted High ............................. 73

CID 0774 FMI 04 Throttle Demand Sensor No.2

Shorted Low ........................................................ 73

CID 0774 FMI 08 Throttle Demand Sensor No.2

Abnormal Signal .................................................. 73

CID 0774 FMI 12 Throttle Demand Sensor No.2 Out

Of Calibration ...................................................... 74

CID 1627 FMI 03 Fuel Injection Pump Relay Did Not

Turn Off ............................................................... 74

CID 1684 FMI 00 Fuel Injection Pump, Fuel

Temperature More Than Normal ......................... 74

CID 1684 FMI 02 Fuel Injection Pump, Software

Failure ................................................................. 75

4 Table of Contents

CID 1684 FMI 03 Fuel Injection Pump, Fuelling

Fault .................................................................... 75

CID 1684 FMI 04 Fuel Injection Pump, Supply

Voltage Fault ....................................................... 76

CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse

Width ................................................................... 76

CID 1684 FMI 07 Fuel Injection Pump, Mechanical

Fault .................................................................... 77

CID 1684 FMI 08 Fuel Injection Pump, Crankshaft

Reference Fault ................................................... 77

CID 1684 FMI 09 Fuel Injection Pump, CAN

Fault .................................................................... 78

CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff

Signal Error ......................................................... 78

CID 1684 FMI 11 Fuel Injection Pump, Internal

Sensor Fault ........................................................ 79

CID 1684 FMI 12 Fuel Injection Pump, Device

Failure ................................................................. 80

CID 1684 FMI 14 Fuel Injection Pump, No

Communications ................................................. 80

CID 1743 FMI 02 Engine Speed Mode Selection

Switch State, Invalid State .................................. 81

CID 1894 FMI 02 Set Speed Control Disengage

Switch State, Invalid State .................................. 81

CID 1895 FMI 02 Set Speed Control Speed Toggle

Switch, Invalid State ............................................ 81

Engine Temperature Sensor Open or Short Circuit -

Test ................................................................... 168

Fuel Injection Pump Circuit - Test ....................... 175

Indicator Lamp Circuit - Test ............................... 192

Mode Selection Circuit - Test .............................. 195

Set Speed Circuit - Test ...................................... 202

Throttle Switch Circuit - Test ............................... 210

Index Section

Index ................................................................... 219

Troubleshooting with an Event Code

Event Codes ........................................................ 83

E015 High Engine Coolant Temperature Derate ... 83 E016 High Engine Coolant Temperature

Shutdown ............................................................ 83

E017 High Engine Coolant Temperature

Warning ............................................................... 83

E025 High Intake Air Temperature Derate ............ 84

E027 High Intake Air Temperature Warning ......... 84

E040 Low Engine Oil Pressure Shutdown ............ 85

E054 High Fuel Temperature Derate .................... 85

E056 High Fuel Temperature Warning .................. 86

E100 Low Engine Oil Pressure Warning ............... 87

E190 Engine Overspeed Warning ........................ 88

E442 Engine Failed to Stop with a No-Fuel

Command ........................................................... 88

E883 Engine Failed To Stop When Fuel Solenoid

Disengaged ......................................................... 89

Diagnostic Functional Tests

5 Volt Engine Pressure Sensor Supply Circuit -

Test ..................................................................... 90

Air Inlet Heater Circuit - Test ................................. 97

Analog Throttle Position Sensor Circuit - Test .... 102

CAN Data Link Circuit - Test ............................... 111

Data Link Circuit - Test ........................................ 116

Digital Throttle Position Sensor Circuit - Test ...... 124

Electrical Connectors - Inspect ........................... 133

Electrical Power Supply Circuit - Test ................. 144

Engine Oil Level Switch Circuit - Test ................. 149

Engine Pressure Sensor Open or Short Circuit -

Test ................................................................... 154

Engine Speed/Timing Sensor Circuit - Test ........ 161

Troubleshooting Section

Electronic Troubleshooting

i01798100

System Overview

System Operation

The 1104 models RF, RH, RK and 1106 model VK engines were designed for electronic control. The engines include an Electronic Control Module (ECM), a fuel injection pump that is electronically controlled, and a collection of engine sensors. The ECM controls the engine operating parameters through the software within the ECM and the inputs from the various sensors. The software contains parameters that control the engine operation. The parameters include all of the operating maps and customer selected parameters.

Troubleshooting Section

6 Troubleshooting Section

Electronic Controls

Illustration 1

g00908788

Troubleshooting Section

Illustration 2

The electronic system consists of the Electronic Control Module (ECM), the engine sensors, and the Machine Interface Connector (MIC). The ECM is the computer. The personality module is the software for the computer. The personality module contains the operating maps. The operating maps define the following characteristics of the engine:

Horsepower

•

Torque curves

•

Engine speed (rpm)

•

Engine Governor

The electronic controls determine the injection timing and the amount of fuel that is delivered to the cylinders. These decisions are based on the actual conditions and the desired conditions at any given time.

g00954204

The governor compares the desired engine speed to the actual engine speed. The actual engine speed is determined through the crankshaft position sensor. If the desired engine speed is greater than the actual engine speed, the governor injects more fuel in order to increase engine speed.

Timing Considerations

Once the governor has determined the amount of fuel that is required, the governor must determine the timing of the fuel injection. Fuel injection timing is determined by the ECM after considering input from the following components:

Engine coolant temperature sensor

•

The sensor for the intake manifold air temperature

•

The sensor for the intake manifold pressure

•

8 Troubleshooting Section

At start-up, the ECM determines the top dead center position of the number 1 cylinder from the speed/timing sensor in the fuel injection pump. The ECM decides when fuel injection should occur relative to the top dead center position. The ECM provides the signal to the fuel injection pump spill valve which stops fuel flow to the low pressure side. The ECM then forces fuel to flow to the fuel injector nozzles at the desired time. The ECM adjusts timing for the best engine performance, the best fuel economy and the best control of exhaust emissions. Actual timing cannot be viewed with an electronic service tool. Also, the desired timing cannot be viewed with an electronic service tool.

Fuel Injection

The personality module inside the ECM sets certain limits on the amount of fuel that can be injected. The FRC Limit is a limit that is based on intake manifold air pressure and engine rpm. The FRC Limit is used to control the air/fuel ratio in order to control the engine’s exhaust emissions. When the ECM senses a higher intake manifold air pressure, the ECM increases the FRC Limit. A higher intake manifold air pressure indicates that there is more air in the cylinder. When the ECM increases the FRC Limit, the ECM allows more fuel into the cylinder.

The Rated Fuel Limit is a limit that is based on the power rating of the engine and on the engine rpm. The Rated Fuel Limit enables the engine power and torque outputs to conform to the power and torque curves of a specific engine model.

These limits are in the personality module and these limits cannot be changed.

Diagnostic Codes

When the ECM detects an engine problem, the ECM generates a diagnostic code. Also, the ECM logs the diagnostic code in order to indicate the time of the problem’s occurrence. The ECM also logs the number of occurrences of the problem. There are two types of diagnostic fault codes. There are fault codes and event codes.

Diagnostic Fault Codes

Diagnostic fault codes are provided in order to indicate that an electrical problem or an electronic problem has been detected by the ECM. In some cases, the engine performance can be affected when the condition that is causing the code exists. More frequently, the operator cannot detect any difference in the engine performance.

If the operator indicates that a performance problem occurs, the diagnostic code may indicate the cause of the problem. Use either a laptop computer or a hand held diagnostic tool to access the diagnostic codes. The problem should then be corrected.

If the operator does not indicate a problem with the engine performance and a diagnostic code is logged by the ECM. This situation indicates that the ECM detected an abnormal engine condition, but the abnormal condition did not affect engine performance. In this situation, the system has no faults except when either of the following conditions exist:

There are several occurrences of the diagnostic

•

code in a very short period of time.

The ECM is indicating an active code at the

•

present time.

Diagnostic Event Codes

Diagnostic event codes are used to indicate that some operational problem has been detected in the engine by the ECM. This does not indicate an electronic malfunction.

Programmable Parameters

Certain parameters that affect the engine operation may be changed with electronic service tools. The parameters are stored in the ECM, and the parameters are protected from unauthorized changes by passwords. These parameters are System Configuration Parameters.

System Configuration Parameters are set at the factory. System Configuration Parameters affect emissions or power ratings within the engine. Factory passwords must be obtained and factory passwords must be used to change the System Configuration Parameters.

Passwords

System Configuration Parameters are protected by factory passwords. Factory passwords are calculated on a computer system that is available only to Perkins distributors. Since factory passwords contain alphabetic characters, only an electronic service tool may change System Configuration Parameters. System Configuration Parameters affect the power rating or the emissions.

Refer to Troubleshooting, “Programming Parameters” and Troubleshooting, “Factory Passwords”.

Troubleshooting Section

i01798101

Glossary

Active Diagnostic Code – An active diagnostic code alerts the operator or the service technician that an electronic system malfunction is currently present. Refer to the term “Diagnostic Code” in this glossary.

Alternating Current (AC) – Alternating current is an electric current that reverses direction at a regular interval that is reoccurring.

Before Top Dead Center (BTC) – BTDC is the 180 degrees of crankshaft rotation before the piston reaches the top dead center position in the normal direction of rotation.

Boost Pressure (Engines that are turbocharged) –

The difference between the turbocharger outlet pressure and atmospheric pressure is commonly referred to as boost pressure. The sensor for the intake manifold air pressure measures the amount of boost.

Breakout Harness – The breakout harness is a test harness that is designed to connect into the engine harness. This connection allows a normal circuit operation and the connection simultaneously provides a Breakout T in order to measure the signals.

Bypass Circuit – A bypass circuit is a circuit that is used as a substitute circuit for an existing circuit. A bypass circuit is typically used as a test circuit.

CAN Data Link – The CAN Data Link is a serial communications port that is used for communication with other microprocessor based devices. In this application, the CAN Data Link connects the ECM to the Electronic Fuel Injection Pump.

Code – Refer to “Diagnostic Code” or “Event Code”.

Cold Mode – Cold mode is a mode for cold starting

and for cold engine operation that includes timing that is retarded and low idle that is raised. This mode is used for engine protection, reduced smoke emissions and faster warm up time.

Communication Adapter Tool – The communication adapter provides a communication link between the ECM and the Electronic Service Tool.

Coolant Level Sensor – The coolant level sensor detects the absence or presence of coolant at the probe. The sensor then sends a signal to the ECM.

Coolant Temperature Sensor – The coolant temperature sensor detects the engine coolant temperature for cold mode operation and for Engine Monitoring.

Data Link – The Data Link is a serial communication port that is used for communication with other microprocessor based devices.

Desired Engine Speed – The desired engine speed is input to the electronic governor within the ECM. The electronic governor uses the signal from the throttle position sensor, the engine speed/timing sensor, and other sensors in order to determine the desired engine speed.

Diagnostic Code – A diagnostic code is sometimes referred to as a fault code. These codes indicate an electronic system malfunction.

Diagnostic Lamp – A diagnostic lamp is sometimes called the check engine light. The diagnostic lamp is used to warn the operator of the presence of an active diagnostic code.

Digital Sensor Return – The common line (ground) from the ECM is used as ground for the digital sensors.

Digital Sensors – Digital sensors produce a pulse width modulated signal. Digital sensors are supplied with +8 VDC from the ECM.

Digital Sensor Supply – The +8 VDC supply from the ECM is used in order to power the digital sensors.

Direct Current (DC) – Direct current is the type of current that flows consistently in only one direction.

DT, DT Connector, or Deutsch DT – This is a type of connector that is used on Perkins engines. The connectors are manufactured by Deutsch.

Duty Cycle – Refer to “Pulse Width Modulation”.

Electronic Engine Control – The electronic engine

control is a complete electronic system. The electronic engine control monitors the engine operation under all conditions. The electronic engine control also controls the engine operation under all conditions.

Component Identifier (CID) – The CID is a number that identifies the specific component of the electronic control system that has experienced a diagnostic code.

Electronic Service Tool – The electronic service tool allows a computer (PC) to communicate with the ECM.

10 Troubleshooting Section

Electronic Control Module (ECM) – The ECM is the

control computer of the engine. The ECM provides power to the electronics. The ECM monitors data that is input from the sensors of the engine. The ECM acts as a governor in order to control the speed and the power of the engine.

Engine Monitoring – Engine Monitoring is the part of the electronic engine control that monitors the sensors. This also warns the operator of detected problems.

Engine Oil Pressure Sensor – The engine oil pressure sensor measures engine oil pressure. The sensor sends the signal to the ECM.

Engine Speed/Timing Sensor – The engine speed/timing sensor provides a variable amplitude and pulse width modulated signal to the ECM. The ECM interprets this signal as the crankshaft position and the engine speed.

Event Code – An event code may be activated in order to indicate an abnormal engine operating condition. These codes usually indicate a mechanical problem instead of an electrical system problem.

Failure Mode Identifier (FMI) – This identifier indicates the type of failure that has been experienced by the component. The FMI has been adopted from the SAE practice of J1587 diagnostics.

Flash Programming – Flash programming is the method of programming or updating an ECM with an electronic service tool over the data link instead of replacing components.

Fuel Ratio Control (FRC) – The FRC is a limit that is based on the control of the ratio of the fuel to air. The FRC is used for purposes of emission control. When the ECM senses a higher intake manifold air pressure (more air into the cylinder), the FRC increases the FRC Limit (more fuel into the cylinder).

Fuel Temperature Sensor – The fuel temperature sensor detects the fuel temperature. The ECM monitors the fuel temperature and the ECM adjusts the calculated fuel rate accordingly.

Full Load Setting (FLS) – The FLS is the number that represents the fuel system adjustment. This adjustment is made at the factory in order to fine tune the fuel system. The correct value for this parameter is stamped on the engine information ratings plate. This parameter must be programmed.

Harness – The harness is the bundle of wiring (loom) that connects all components of the electronic system.

Hertz (Hz) – Hertz is the measure of electrical frequency in cycles per second.

Intake Manifold Air Temperature Sensor – The intake manifold air temperature sensor detects the air temperature in the intake manifold. The ECM monitors the air temperature and other data in the intake manifold in order to adjust injection timing and other performance functions.

Intake Manifold Pressure Sensor – The air pressure in the intake manifold may be different to the air pressure outside the engine (atmospheric pressure). This difference in air pressure can be caused by variable air velocity within the manifold. The difference in pressure can also be caused by an increase in air pressure by a turbocharger (if equipped). The sensor for the intake manifold air pressure measures the difference between atmospheric pressure and the air pressure in the intake manifold.

Integrated Electronic Controls – The engine is designed with the electronic controls as a necessary part of the system. The engine will not operate without the electronic controls.

J1939 CAN Data Link – This data link is a SAE diagnostic communications data link that is used to communicate between the ECM and the electronic service tool.

Logged Diagnostic Codes – Logged diagnostic codes are codes which are stored in the memory. These codes are meant to be an indicator of possible causes for intermittent problems. Refer to the term “Diagnostic Code” in this glossary for more information.

MAB – This is a Bosch acronym for the fuel shutoff inside the “VPM30” Fuel Injection Pump. The MAB is a signal wire from the ECM to the Fuel Injection Pump.

Open Circuit – An open circuit is a condition that is caused by an open switch, or by an electrical wire or a connection that is broken. When this condition exists, the signal or the supply voltage can no longer reach the intended destination.

Parameter – A parameter is a value or a limit that is programmable. This helps determine specific characteristics or behaviors of the engine.

Full Torque Setting (FTS) – The FTS is similar to the full load setting. This parameter must be programmed.

Troubleshooting Section

Password – A password is a group of numeric

characters or a group of alphanumeric characters that is designed to restrict access to parameters. The electronic system requires correct passwords in order to change some parameters (Factory Passwords). Refer to Troubleshooting, “Factory Passwords” for more information.

Personality Module – This module is inside the ECM. The module contains all the instructions (software) for the ECM and the module contains the performance maps for a specific engine. The personality module may be reprogrammed through flash programming.

Power Cycled – Power cycled happens when power to the ECM is cycled: ON, OFF, and ON. Power cycled refers to the action of cycling the keyswitch from any position to the OFF position, and to the START/RUN position.

Pulse Width Modulation (PWM) – The PWM is a signal that consists of pulses that are of variable width. These pulses occur at fixed intervals. The ratio of “TIME ON” versus total “TIME OFF” can be varied. This ratio is also referred to as a duty cycle.

Short Circuit – A short circuit is a condition that has an electrical circuit that is inadvertently connected to an undesirable point. An example of a short circuit is a wire which rubs against a vehicle frame and this rubbing eventually wears off the wire insulation. Electrical contact with the frame is made and a short circuit results.

Signal – The signal is a voltage or a waveform that is used in order to transmit information typically from a sensor to the ECM.

Supply Voltage – The supply voltage is a constant voltage that is supplied to a component in order to provide the electrical power that is required for the component to operate. The power may be generated by the ECM or the power may be battery voltage that is supplied by the engine wiring.

System Configuration Parameters – System configuration parameters are parameters that affect emissions and/or operating characteristics of the engine.

Throttle Position – The throttle position is the interpretation by the ECM of the signal from the throttle position sensor or the throttle switch.

Illustration 3

g00284479

Rated Fuel Limit – This term indicates the maximum allowable fuel position (longest injection pulse). This position will produce rated power for this engine configuration.

Reference Voltage – Reference voltage is a regulated voltage and a steady voltage that is supplied by the ECM to a sensor. The reference voltage is used by the sensor to generate a signal voltage.

Sensor – A sensor is a device that is used to detect a change in pressure, temperature, or mechanical movement. The information that is detected is converted into an electrical signal.

Throttle Position Sensor – The throttle position sensor is an electronic sensor that is connected to an accelerator pedal or a hand lever. This sensor sends a PWM signal to the ECM that is used to calculate desired engine speed.

Throttle Switch – The throttle switch sends a signal to the ECM that is used to calculate desired engine speed.

Top Dead Center – Top dead center refers to the crankshaft position when the engine piston position is at the highest point of travel. The engine must be turned in the normal direction of rotation in order to reach this point.

Total Tattletale – The total tattletale is the total number of changes to all the parameters that are stored in the ECM.

Voltage Load Protection Module (“VLPM”) – The “VLPM” monitors the voltage of the electronic system. The “VLPM”will eliminate any high voltage conditions that occur. The “VLPM” will protect the fuel injection pump from any high voltage conditions that could damage the pump.

12 Troubleshooting Section

i01798102

Electronic Service Tools

Electronic Service Tools are designed to help the service technician with the diagnosis and repair of electronic engines. Several tools are available to assist the service technician.

Some of the included Diagnostic Functional Tests in this manual require two short jumper wires. The jumper wires are used to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector.

A long extension wire may also be needed to check the continuity of some wiring harness circuits.

Electronic Service Tool

The electronic service tool can display the following information:

Parameters

•

Event codes

•

Diagnostic codes

•

Ta bl e 1

Required Electronic Service Tools for the Use

Part

Number

of the Electronic Service Tool

Required

IBM compatible PC with 266 MHz Pentium processor

64 MB of RAM

N/A

400 MB of available hard drive space CD-ROM drive

3.5" 1.44 MB floppy disk drive VGA monitor or display (800 x 600) Microsoft NT 4.0, 98, or 95 RS232 port with 16550AF UART

Recommended

IBM compatible PC with 450 MHz Pentium III processor

128 MB of RAM 1 GB of available hard drive space 40X speed CD-ROM drive or 8X speed DVD drive

3.5" 1.44 MB floppy disk drive Super VGA monitor or display (800 x 600) Microsoft NT 4.0, or 98 RS232 port with 16550AF UART

Windows 2000, XP, ME,

Description

Engine configuration

•

The electronic service tool can be used by the technician to perform the following functions:

Diagnostic tests

•

Sensor calibrations

•

Flash programming

•

Set parameters

•

The following components are required to use the electronic service tool to service the engine.

Troubleshooting Section

Connecting the Electronic Service Tool and the Communication Adapter II

Support for the Electronic Service Tool

For authorization and ordering information, contact Perkins Help Desk - Irlam.

If you are having problems with the software, you can contact the Perkins Service Systems Support Center.

Optional Service Tools

The following table contains service tools that may be helpful to service the engine.

Ta bl e 2

Optional Service Tools

Part Number Description

N/A N/A Suitable Breakout T (70 pin) N/A Suitable Crimp Tool N/A Suitable Cylinder Pressure Indicator N/A Suitable Battery Load Tester

Suitable Digital Multimeter

Illustration 4 (1) Personal computer (PC)

(2) Adapter Cable (Computer Serial Port) (3) Communication Adapter II (4) Adapter Cable Assembly

g00647144

Note: Items (2), (3), and (4) are part of the Communication Adapter II Gp.

Use the following procedure to connect the Electronic Service Tool and the Communication Adapter II.

1. Turn the keyswitch to the OFF/RESET position. If

the keyswitch is not placed in the OFF/RESET position, the engine may start.

2. Connect cable (2) between the “COMPUTER”

end of communication adapter (3) and the RS232 serial port of PC (1).

3. Connect cable (4) between the “DATA LINK” end

of communication adapter (3) and the service tool connector.

4. Turn the keyswitch to the ON position. If the

electronic service tool and the communication adapter do not communicate with the ECM, refer to Troubleshooting, “Electronic Service Tool Will Not Communicate With ECM”.

i01879254

Diagnostic Codes

This list identifies the respective faults for the CID FMI and the J Code FMI codes. The CID FMI codes are displayed on a laptop computer. The J Code FMI codes are displayed on a Diagnostic Code Reader. The Diagnostic Code Reader is also known as the Hand Held Tool.

The Component Identifier (CID) is a number that identifies the specific component that caused a diagnostic code to be logged.

The Failure Mode Identifier (FMI) is a number that indicates the type of failure that has been experienced by the component.

The J1939 Code is another system that identifies the specific component that caused a diagnostic code to be logged.

Note: Event codes are not supported by J1939 numbers. Event codes use (CID) and (FMI) numbers. The following (FMI) numbers 0, 1, 15, 16, 17, and 18 are used for event codes.

14 Troubleshooting Section

Ta bl e 3

CID FMI Code

0041 03 0041 04 0091 02 0091 03 0091 04 0091 08 0091 12 0100 03 0100 04 0100 10 0102 03 0102 04 0102 10 0105 03 0105 04 0110 03 0110 04 0168 02 0174 02 0247 09 0253 02 0262 03 0262 04 0266 02 0267 02 0320 02 0320 11 0321 02 0342 02 0590 02 0774 02 0774 03 0774 04 0774 08 0774 12 1627 03 1639 09 1684 00

J Code FMI Code Fault Description

J0678 03 8V Sensor Power Supply, voltage more than normal J0678 04 8V Sensor Power Supply, voltage less than normal J0091 02 Throttle Demand Sensor, erratic or intermittent J0091 03 Throttle Demand Sensor, open circuit or shorted high J0091 04 Throttle Demand Sensor, shorted low J0091 08 Throttle Demand Sensor, abnormal signal J0091-12 Throttle Demand Sensor, power supply failure J0100 03 Engine Oil Pressure Sensor, open circuit or shorted high J0100 04 Engine Oil Pressue Sensor, shorted low

Engine Oil Pressure Sensor, power supply open circuit J0102 03 Intake Manifold Pressure Sensor, open circuit or shorted high J0102 04 Intake Manifold Pressure Sensor, shorted low

Intake Manifold Pressure Sensor, power supply open circuit J0105 03 Intake Manifold Temperature Sensor, open circuit or shorted high J0105 04 Intake Manifold Temperature Sensor, shorted low J0110 03 Engine Coolant Temperature Sensor, open circuit or shorted high J0110 04 Engine Coolant Temperature Sensor, shorted low J0168 02 Battery Voltage, intermittent or incorrect J0174 02 Fuel Temperature Sensor, erratic or intermittent J0639 09 J1939 Datalink, abnormal update J0234 02 Incorrect ECM Software J0620 03 5V Sensor Power Supply, voltage more than normal J0620 04 5V Sensor Power Supply, voltage less than normal

Crank without injection, switch state incorrect

External Stop Switch, data erratic or incorrect J0637 02 Speed and Timing Sensor, intermittent loss of signal J0637 11 Speed and Timing Sensor, loss of signal

Diagnostic Reset Switch, intermittent or incorrect J0723 02 Speed and Timing Sensor No.2, intermittent signal

ECM identified missing timing pulse

Throttle Demand Sensor No.2, erratic or intermittent

Throttle Demand Sensor No.2, open circuit or shorted high

Throttle Demand Sensor No.2, shorted low

Throttle Demand Sensor No.2, abnormal signal

Throttle Demand Sensor No.2, power supply failure

Fuel Pump Relay, did not turn off

Machine Security System Module, abnormal update J1077 00 Fuel Injection Pump, fuel temperature more than normal

(continued)

(Table 3, contd)

1684 02 1684 03 1684 04 1684 05 1684 07 1684 08 1684 09 1684 10 1684 11 1684 12 1684 14 1690 08 1743 02 1894 02 1895 02

Event Code CID FMI Code

E015 E016 E017 E025 E027 E039 E040 E054 E056 E100 E190 E442 Engine Failed To Stop With A No-Fuel Command E883 Engine Failed To Stop When Fuel Solenoid Disengaged

J1077 02 Fuel Injection Pump, software failure J1077 03 Fuel Injection Pump, fuelling fault J1077 04 Fuel Injection Pump, supply voltage fault J1077 05 Fuel Injection Pump, invalid pulse width J1077 07 Fuel Injection Pump, mechanical fault J1077 08 Fuel Injection Pump, crankshaft reference fault J1077 09 Fuel Injection Pump, CAN fault J1077 10 Fuel Injection Pump, fuel shutoff signal error J1077 11 Fuel Injection Pump, internal sensor fault J1077 12 Fuel Injection Pump, device failure J1077 14 Fuel Injection Pump, no communications

Analogue Speed Control, signal abnormal

Engine Mode Selection Switch State, invalid state

Set Speed Control Disengage Switch, invalid state

Set Speed Control Speed Toggle Switch, invalid state

110 16 110 00 110 15 105 16 105 15 100 18 100 01 174 16 174 15 100 17 190 15

High Engine Coolant Temperature Derate

High Engine Coolant Temperature Sutdown

High Engine Coolant Temperature Warning

High Intake Air Temperature Derate

High Intake Air Temperature Warning

Low Engine Oil Pressure Derate

Low Engine Oil Pressure Shutdown

High Fuel Temperature Derate

High Fuel Temperature Warning

Low Engine Oil Pressure Warning

Engine Overspeed Warning

Troubleshooting Section

i01878735

Indicator Lamps

Some engine applications are equipped with Indicator Lamps. Indicator lamps can be used as a diagnostic aid. There are two lamps. One lamp has an orange lens and the other lamp has a red lens.

These indicator lamps can be used in two ways:

The indicator lamps can be used to identify the

•

current operational status of the engine. The indicator lamps can also be used to indicate that the engine has a fault. This system is automatically operated via the ignition switch.

The indicator lamps can be used to identify active

•

diagnostic codes. This system is activated by pressing the Flash Code button.

16 Troubleshooting Section

Use the lamps to check the engine’s operational status or the existence of any engine faults.

Each lamp will be illuminated in a combination of ways in order to identify the engine’s operational status. The lamps will also be illuminated in a combination of ways to indicate if the engine has a fault. These combinations of illuminated lamps have the following meanings:

The status of the lamps before the engine is cranked. This also acts as a lamp check.

When the ignition switch is turned ON, the lamps will be illuminated for 2 seconds. The lamps are then OFF unless the cold starting aid is required.

Ta bl e 4

Orange

lamp

(status)

ON ON The lamps will be illuminated

Refer to the

comments.

The lamp status with the cold starting aid in operation and before the engine is cranked.

Red lamp

(status)

for 2 seconds or the lamps will be illuminated until the engine is cranked.

OFF The lamp will be OFF unless

the cold starting aid is required.

Comments

Ta bl e 6

Orange

lamp

(status)

OFF OFF There are no apparent

ON ON The lubricating oil pressure

Red lamp

(status)

Comments

problems.

is low. This low oil pressure was measured after the set delay had expired.

The status of the lamps after cranking has failed to start the engine.

Ta bl e 7

Orange

lamp

(status)

OFF OFF No faults were detected.

ON OFF An electrical fault was

OFF Flashing The engine was activated

Red lamp

(status)

Comments

detected.

when a serious fault was detected.

Other combinations of illuminated indicator lamp

The following combinations of lamp status may also be exhibited when the engine is either running or when the engine has been shut down automatically.

The orange lamp will be illuminated until the engine is ready to be cranked.

Ta bl e 5

Orange

lamp

(status)

ON OFF The status of the lamps with

Then OFF OFF This is the status of the

Red lamp

(status)

Comments

the cold starting aid still operating.

lamps while the engine is being cranked. The cold starting aid is no longer operating.

This is the status of the lamps while the engine is being cranked.

Unless there is a fault, the engine monitoring system will not illuminate the indicator lamps while the engine is being cranked. For example if there is a lack of lubricating oil pressure after the start delay is exceeded. This type of fault will cause the stop lamp for the engine to be illuminated.

Troubleshooting Section

Ta bl e 8

Orange

lamp

(status)

OFF OFF No faults were detected. OFF ON The oil pressure is low.

Flashing OFF Either the coolant temperature

OFF Flashing Either a fault has caused the

ON OFF An electrical fault has been

ON ON The oil pressure is low and

ON Flashing Either a fault has caused the

Flashing ON The oil pressure is low and

Red lamp

(status)

Comments

is high or the intake air temperature is high. The engine may be derated.

engine to be automatically shut down or the engine has exceeded the condition for a derate.

detected.

there is an electrical fault.

engine to shut down or the engine has exceeded the conditions for a derate. There is also an electrical fault.

either the coolant temperature or the intake air temperature is high. The engine may be derated.

Use the lamps to identify active diagnostic codes.

Ta bl e 9

CID

number

0041 0091 0100 0102

0105

0110

0174 0247 0253 0262 0320 0342

0774

1684 1743

1894 1895

Description Flash

8 Volt Power Supply Throttle Position Sensor Engine Oil Pressure Sensor Intake Manifold Pressure

Sensor Intake Manifold Air Temperature

Sensor Engine Coolant Temperature

Sensor Fuel Temperature Sensor J1939 Data Link Personality Module 5 Volt Power Supply Engine Speed/Timing Sensor Secondary Engine Speed

Sensor Secondary Throttle Position

Sensor Fuel Injection Pump Mode Selector Switch for

Engine Operation Cruise Control Status Switch Toggle Switch for Cruise

Control Speed

code

517 154 157 135

133

168

165 514 416 516 141 142

155

158 144

427 428

The indicator lamps can be used to identify an active code by flashing in a sequence that will identify the active code. The active code that is flashed by the indicator lamps is only the component identifier (CID). The indicator lamps cannot identify the fault with the component. The active code that is flashed by the indicator lamps is not a Failure Mode Identifier (FMI).

When the Flash Code feature is activated the indicator lamps will flash the codes of all active codes. Activation of the indicator lamps is achieved by cycling the keyswitch OFF and ON twice within 3 seconds.

There will be a delay of 2 seconds before the lamps start to flash the identity of any active code.

An active CID with two digits will be flashed in the following sequence. There will be a number of flashes. The number of flashes will equal the first digit. There will be a delay before a second number of flashes. The second number of flashes will equal the second digit. For example, a CID code of 41 will be four flashes, a delay and the one flash. A three digit CID code will have two delays between the sequence of flashes. A four digit CID code will have three delays between the sequence of flashes.

Each flash of the lamp will be 0.5 seconds long.

There will be a delay between each flash of 0.3 seconds.

18 Troubleshooting Section

Each delay between each digit of the code will be 2 seconds.

After one active code has been identified there will be a delay of 5 seconds before the next active code is flashed.

The sequence of flashing the active codes may be restarted at any time by reactivating the cycling of the keyswitch.

i01798103

Replacing the ECM

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

The engine is equipped with an Electronic Control Module (ECM). The ECM contains no moving parts. Follow the troubleshooting procedures in this manual in order to be sure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem.

Note: Ensure that the ECM is receiving power and that the ECM is properly grounded before replacement of the ECM is attempted. Refer to Troubleshooting, “Electrical Power Supply Circuit Test”.

A test ECM can be used in order to determine if the ECM on the engine is faulty. Install a test ECM in place of the suspect ECM. Flash the personality module into the test ECM. Program the parameters for the test ECM. The parameters must match the parameters in the suspect ECM. Refer to the following test steps for details. If the test ECM resolves the problem, reconnect the suspect ECM. Verify that the problem returns. If the problem returns, replace the ECM.

Use the electronic service tool to read the parameters in the suspect ECM. Record the parameters in the suspect ECM. The personality module can be flashed into the new ECM. After the ECM is installed on the engine, the parameters must be programmed into the new ECM.

Note: When a new ECM is not available, you may need to remove an ECM from an engine that is not in service. The ECM must have the same serial number suffix. Ensure that the replacement ECM and the Personality Module Interlock Code match the suspect ECM. Be sure to record the parameters from the replacement ECM. Use the “Copy Configuration ECM Replacement” function in the electronic service tool.

NOTICE If the Personality Module and engine application are not matched, engine damage may result.

Perform the following procedure in order to replace the ECM.

1. Connect the electronic service tool to the service

tool connector.

2. Use the “Copy Configuration ECM Replacement”

function from the electronic service tool. If the “Copy Configuration” is successful, proceed to Step 4. If the “Copy Configuration” failed, proceed to Step 3.

Note: You may want to record any Logged Faults and Events for your records.

3. Record the parameters. Record all of the

parameters on the “Main Configuration” screen. Also, record all of the parameters on the “Throttle Configuration” screen and on the “Mode Configuration” screen.

Note: If the parameters cannot be read, the parameters must be obtained elsewhere. Some parameters are stamped on the engine information plate, but most parameters must be obtained from the factory.

4. Remove the ECM.

a. Turn the keyswitch to the OFF position.

b. Turn the battery disconnect switch to the OFF

position.

c. Slacken the 4 mm Allen head screw

and disconnect the ECM 70-pin (P1/J1) connectors.

d. Remove the mounting bolts from the ECM.

e. Disconnect the grounding strap from the ECM.

5. Install the replacement ECM.

Troubleshooting Section

a. Use the old mounting hardware to install the

replacement ECM. The mounting hardware should be free of damage.

b. Check that the ECM mounting hardware is

installed correctly. The rubber grommets are used to protect the ECM from excessive vibration. The ECM should be able to drift in the rubber grommets.

c. Install the ground strap for the ECM on the

engine.

d. Reconnect the J1/P1 70 Pin connector to the

ECM. Tighten the Allen head screw on the connectors to a torque of 6 N·m (55 lb in).

6. Download the Flash file.

a. Connect the electronic service tool to the

service connector.

b. Select “WinFlash” from the “Utilities” menu of

the electronic service tool.

c. Select the appropriate file.

7. If it is necessary, use the electronic service tool

to clear the rating interlock in the Personality Module. To clear the rating interlock, enter the factory password when the electronic service tool is first connected. Activating the “Test ECM” mode will also clear the rating interlock.

8. Use the electronic service tool to program the parameters. Perform the following procedure.

a. If the “Copy Configuration” procedure was

successful, use the “Copy Configuration, ECM Replacement” function to load the configuration file into the ECM.

Event

•

Diagnostic Code – When a problem with the electronic system is detected, the ECM generates a diagnostic code. This indicates the specific problem with the circuitry.

Diagnostic codes can have two different states:

Active

•

Logged

•

Active Code – An active diagnostic code indicates that an active problem has been detected. Active codes require immediate attention. Always service active codes prior to servicing logged codes.

Logged Code – Every generated code is stored in the permanent memory of the ECM. The codes are logged.

Event Code – An event code is generated by the detection of an abnormal engine operating condition. For example, an event code will be generated if the oil pressure is too low. In this case, the event code indicates the symptom of a problem.

Logged codes may not indicate that a repair is needed. The problem may have been temporary. The problem may have been resolved since the logging of the code. If the system is powered, it is possible to generate an active diagnostic code whenever a component is disconnected. When the component is reconnected, the code is no longer active. Logged codes may be useful to help troubleshoot intermittent problems. Logged codes can also be used to review the performance of the engine and the electronic system.

b. If the “Copy Configuration” procedure failed,

configure the parameters individually. The parameters should match the parameters from step 2.

9. Check for logged diagnostic codes. Factory passwords are required to clear Logged Events.

i01798104

Self-Diagnostics

The Electronic Control Module (ECM) has the ability to detect problems with the electronic system and with engine operation. When a problem is detected, a code is generated. An alarm may also be generated. There are two types of codes:

Diagnostic

•

20 Troubleshooting Section

Sensors and Electrical Connectors

i01798105

Illustration 5 1104 Typical example of left side sensor locations

g00954205

Troubleshooting Section

Illustration 6 1104 engine Typical location of the VLPM

g00915379

Illustration 7 1104 Typical example of right side sensor locations

g00882117

22 Troubleshooting Section

Illustration 8 1106 Typical example of left side sensor locations

g00884570

Troubleshooting Section

Illustration 9 1106 engine Typical location of the VLPM

g00908929

24 Troubleshooting Section

Illustration 10 Typical example of right side sensor locations 1106

g00954214

Ta bl e 1 0

Connector

Function

J1/P1 ECM Connector 70 Pin Machine

Harness

J20/P20 Machine Interface Connector

(70-Pin Engine Harness)

J40/P40 Fuel Injection Pump (3-Pin

Connector)

J100/P100 Engine Coolant Temperature

Sensor (2-Pin Connector)

J103/P103 Intake Manifold Air Temperature

Sensor (2-Pin Connector)

J200/P200 Intake Manifold Pressure Sensor

(3-Pin Connector)

J201/P201 Engine Oil Pressure Sensor

(3-Pin Connector)

J401/P401 Speed/Timing Sensor (2-Pin

Connector)

Troubleshooting Section

Illustration 11 Basic engine schematic

g00954204

26 Troubleshooting Section

i01798106

Engine Wiring Information

The wiring diagrams are revised periodically. The wiring diagrams will change with updates to the wiring harness. For the most current information, always check the revision number of the diagram. Use the diagram with the latest revision number.

Illustration 12 Schematic for the fuel injection pump and ECM power supply

g00910876

Troubleshooting Section

Illustration 13

g00955504

28 Troubleshooting Section

Illustration 14

g00955499

Note: Each terminal end of the J1939 CAN data link must be connected with a 120 ohm terminating resistor.

Note: Digital outputs 7,8,9,10,11,12,13, and 14 are only suitable for a 12 V system.

Harness Wire Identification

Perkins identifies all wires with eleven solid colors. The circuit number is stamped on the wire at a 25 mm (1 inch) spacing. Table 11 lists the wire colors and the color codes.

Ta bl e 1 1

Color Codes for the Harness Wire

Color Code Color Color Code Color

BK BR Brown BU Blue RD Red PU Purple OR Orange GY Gray YL Yellow WH White

Black GN Green

PK Pink

Troubleshooting Section

For example, a wire identification of F702-GN on the schematic would signify a green wire with the circuit number F702. F702-GN identifies the power supply for the 8 V throttle sensor.

Note: Always replace a harness wire with the same gauge of wire and with the same color code.

30 Troubleshooting Section

Programming Parameters

i01798107

Programming Parameters

The electronic service tool can be used to view certain parameters that can affect the operation of the engine. The electronic service tool can also be used to change certain parameters. The parameters are stored in the Electronic Control Module (ECM). Some of the parameters are protected from unauthorized changes by passwords. Parameters that can be changed have a tattletale number. The tattletale number shows if a parameter has been changed.

i01798108

Factory Passwords

Passwords

Note: The old interlock code is required to change the interlock code on a used ECM. A new interlock code is also required to change the interlock code on a used ECM.

The electronic service tool screen for factory passwords will display the following parameters:

Serial number of the Electronic Control Module

•

(ECM)

Engine serial number

•

Serial number for the electronic service tool

•

Reason Code

•

Total Tattletale number

•

Note: The factory passwords may only be used for one programming session. A different set of factory passwords will be required after you exit the electronic service tool screen. A different set of passwords will be required to change information on another electronic service tool screen.

Customer Passwords

Passwords are part of a security system that helps to prevent unauthorized reprogramming of certain parameters. Passwords prevent unauthorized erasing of logged events. Passwords allow the factory to control access to engine calibration parameters. Passwords allow the customer to control access to certain programmable engine parameters.

Factory Passwords

Factory passwords are required to clear any event code. Factory passwords are required to change certain parameters such as Full Load Setting. The factory passwords restrict changes to authorized personnel. When the correct factory passwords have been entered, the changes can then be made.

In order to obtain the proper factory passwords, certain information must be given to an authorized Perkins distributor. Since the factory passwords contain alphabetic characters, the electronic service tool can be used to perform this function. In order to obtain the factory passwords, proceed as if you already have the factory passwords. At some point, if the factory passwords are actually needed, the electronic service tool will request the factory passwords and the electronic service tool will display the information that is required to obtain the factory passwords.

Customer Passwords allow the customer to restrict access to parameters that are programmable by the customer. The customer passwords cannot be longer than eight characters. The customer has the option of entering one or two customer passwords.

Note: If the owner loses the owner’s customer passwords, the owner will not be able to program parameters that are protected by customer passwords. By using factory passwords, one can read customer passwords. Then use those customer passwords to program parameters that have been protected by customer passwords.

i01798110

Flash Programming

Flash Programming – This is a method of programming or updating the personality module in an ECM.

The electronic service tool can be utilized to flash a new personality module into the ECM. The flash is accomplished by transferring the data from a PC to the ECM.

Flash Programming a Personality Module

1. Connect the electronic service tool to the service

tool connector.

2. Select “WinFlash” from the “Utilities” menu on the electronic service tool.

“WinFlash” will try to detect an ECM.

3. When an ECM has been detected, the “ECM Selector” window will appear. Select the appropriate ECM that needs to be flashed and press “Browse”.

The “Flash File Selection” window will appear.

4. The flash files are located on a disk drive and in a directory. Select the correct disk drive and the correct directory from “Drives” and “Directories” on the electronic service tool.

Troubleshooting Section

A list of flash files will appear.

5. Select the correct file from the list of flash files. Read the “File Info” and the “Description” in order to verify that the correct file is selected. Select “OK”.

6. Select the “Begin Flash” button in order to program the personality module.

When the flash is completed, this message will appear: “Flash Completed Successfully”.

7. Start the engine and check for proper operation.

a. If a diagnostic code of 253-02 Incorrect

ECM Software is generated, program any parameters that were not in the old personality module.

b. Access the “Configuration” screen under

the “Service” menu in order to determine the parameters that require programming. Look under the “Tattletale” column. All of the parameters should have a tattletale of 1 or more. If a parameter has a tattletale of 0, program that parameter.

“WinFlash” Error Messages

If you receive any error messages during flash programming, click on the “Cancel” button in order to stop the process. Access the information about the “ECM Summary” under the “Information” menu. Make sure that you are flashing the correct file for your engine.

32 Troubleshooting Section

System Configuration Parameters

i01798111

System Configuration Parameters

System Configuration Parameters affect the emissions of the engine or the power of the engine. System configuration parameters are programmed at the factory. Normally, system configuration parameters would never need to be changed through the life of the engine. System configuration parameters must be reprogrammed if an ECM is replaced. Unless the engine rating has changed, system configuration parameters do not need to be reprogrammed when the Personality Module is replaced. The correct values for these parameters are stamped on the engine information ratings plate. The engine information ratings plate is located on the valve cover or on the air intake manifold. Factory passwords are required to change these parameters. The following information is a description of the system configuration parameters.

“Full Load Setting”

“Full Load Setting” is a number that represents the adjustment to the fuel system that was made at the factory in order to fine tune the fuel system. The correct value for this parameter is stamped on the engine information ratings plate. If the ECM is replaced, the “full load setting” must be reprogrammed in order to prevent a 253-02 diagnostic code from becoming active.

“Full Torque Setting”

“Full Torque Setting” is similar to “Full Load Setting”. If the ECM is replaced, the full torque setting must be reprogrammed in order to prevent a 253-02 diagnostic code from becoming active.

When an ECM is replaced this rating interlock code must match the code that is stored in the ECM. If the rating interlock code does not match the code that is stored in the ECM, both of the following situations will exist:

The engine will not run.

•

The diagnostic code 253-02 (Incorrect ECM

•

Software) will be active.

Note: The flash programming of a new rating interlock replaces the old rating interlock.

This code does not need to be programmed when the replacement ECM is from the same engine rating.

If the ECM is from a different engine rating, then the following components may need to be changed: pistons, fuel injectors, and other components. The engine information ratings plate must also be changed in order to reflect the new rating.

Some vehicle systems such as the cooling system or the transmission may also require changes when the engine is rerated. Please contact the local OEM dealer for further information.

“Engine Serial Number”

When a new ECM is delivered, the engine serial number in the ECM is not programmed. The “Engine Serial Number” should be programmed to match the engine serial number that is stamped on the engine information plate.

“ECM Software Release Date”

This parameter is defined by the rating interlock and this parameter is not programmable. The “ECM Software Release Date” is used to provide the version of the software. The Customer parameters and the software change levels can be monitored by this date. The date is provided in the month and the year (NOV99). NOV is the month (November). 99 is the year (1999).

Rating Interlock

The Rating Interlock is a code that prevents the use of an incorrect power rating and/or emission rating for a specific engine. Each horsepower rating and each emission certification has a different code to all other horsepower ratings and emission certifications.

Troubleshooting Section

Troubleshooting without a Diagnostic Code

i01798099

Alternator Noise (Noisy Operation)

Note: This is NOT an electronic system problem.

Refer to Testing and Adjusting for information on determining the cause of this condition.

Probable Causes

Alternator drive belts

•

Alternator drive pulley

•

Alternator bearings

•

Recommended Actions

Alternator Drive Belts

i01798098

Alternator Will Not Charge (Charging Problem)

Note: This is NOT an electronic system problem.

Probable Causes

Alternator drive belts

•

Charging circuit

•

Regulator

•

Alternator

•

Recommended Actions

Alternator Drive Belts

1. Inspect the condition of the alternator drive belts.

If the alternator drive belts are worn or damaged, replace the belts. Refer to Disassembly and Assembly, “Alternator - Remove” and Disassembly and Assembly, “Alternator - Install”.

1. Inspect the condition of the alternator drive belts. If the alternator drive belts are worn or damaged, replace the belts. Refer to Disassembly and Assembly, “Alternator - Remove” and Disassembly and Assembly, “Alternator - Install”. Ensure that the alternator drive belts are in alignment. Inspect the alternator mounting bracket for cracks and wear. Repair the mounting bracket or replace the mounting bracket in order to ensure that the alternator drive belts and the alternator drive pulley are in alignment.

2. Check the tension on the alternator drive belts. Adjust the tension, if necessary. Refer to Testing and Adjusting, “V-Belt - Test”.

Alternator Drive Pulley

Loosen the nut for the alternator drive pulley and tighten the nut to the correct torque. Refer to Specifications, “Alternator and Regulator” for the correct torque.

Alternator Bearings

Verify that there is excessive play of the shaft in the alternator and that the alternator bearings are worn. The alternator is a nonserviceable item. The alternator must be replaced if the bearings are worn. Refer to Disassembly and Assembly, “Alternator - Remove” and Disassembly and Assembly , “Alternator - Install”.

Check the tension on the alternator drive belts. Adjust the belt tension if the tension is incorrect. Refer to Testing and Adjusting, “V-Belt - Test”.

Charging Circuit

Inspect the battery cables, wiring, and connections in the charging circuit. Clean all connections and tighten all connections. Replace any faulty parts.

Alternator or Regulator

Verify that the alternator or the regulator is operating correctly. Refer to Testing and Adjusting, “Alternator

- Test”. The alternator is not a serviceable item. The alternator must be replaced if the alternator is not operating correctly.

i01798112

Battery

Note: This is NOT an electronic system problem.

Probable Causes

Faulty battery

•

Auxiliary device drains the battery current.

•

34 Troubleshooting Section

Recommended Actions

Faulty Battery

1. Verify that the battery is no longer able to hold a

charge. Refer to Testing and Adjusting, “Battery

- Test”.

2. Replace the battery. Refer to Operation and Maintenance, “Battery - Replace”.

Auxiliary Device

1. Verify that the auxiliary device drained the battery

by being left in the ON position.

2. Charge the battery.

3. Verify that the battery is able to maintain a

charge.

i01798113

Can Not Reach Top Engine RPM

Recommended Actions

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”.

5. Check that the fuel lines are tight and secured properly.

Note: If this problem occurs only under load, refer to Troubleshooting, “Low Power/Poor or No Response to Throttle”.

Probable Causes

Refer to the logged codes.

•

Fuel supply

•

Air intake and exhaust system

•

Individual malfunctioning cylinders

•

Valve lash

•

Low compression (cylinder pressure)

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

ECM parameters

•

Throttle signal from the throttle position sensor

•

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).

12. If the repairs do not eliminate the problem proceed to “Air Intake and Exhaust System”.



C (32



F), check

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if

equipped.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and the exhaust system for

the following defects:

Blockages

•

Troubleshooting Section

Restrictions

•

Damage to the air intake and exhaust lines

•

and hoses

4. Make all necessary repairs to the engine.

5. Ensure that the repairs have eliminated the

diagnostic code.

6. If the problem has not been eliminated, proceed to “Individual Malfunctioning Cylinders”.

Individual Malfunctioning Cylinders

1. With the engine speed at a fast idle, loosen

the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.

2. Individually repeat this procedure for each fuel injection nozzle. If there is no reduction in the engine speed refer to “Check the Turbocharger (if equipped)”.

3. If all cylinders have been checked and no problems were detected proceed to “Valve Lash”.

Valve Lash

1. Check the valve lash and reset the valve lash, if

necessary. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect and Adjust”.

Worn valves

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

Checking the Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Check the Turbocharger (if equipped)”.

Check the Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable items. If any mechanical fault exists then the turbocharger must be replaced.

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the turbocharger drain is not blocked or restricted.

3. Check that the turbocharger housing is free of dirt and debris.

2. If the repair does not eliminate the fault proceed to “Check for Low Compression”.

Check for Low Compression

1. Remove the fuel injection nozzles and perform a

compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data.

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the faults.

4. If the repair does not eliminate the fault refer to

“Checking the Fuel Injection Nozzles”.

Examples of low compression are shown in the following list:

Mechanical problem

•

Faulty piston rings

•

Worn cylinder bores

•

4. Check the turbocharger for worn bearings. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

5. Check that the turbine blades rotate freely on the turbocharger. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

9. If the fault has not been eliminated proceed to

“ECM Parameters”.

ECM Parameters

1. Ensure that the problem is not a programmed

parameter.

36 Troubleshooting Section

2. Ensure that the correct mode was selected by using the electronic service tool.

3. Use the electronic service tool to verify the correct engine rating for the engine.

4. Use the electronic service tool to verify the maximum engine speed limit.

5. Use the electronic service tool to reset the parameters to the OEM specifications.

6. Ensure that the repairs have eliminated the performance problems.

7. If the repairs have not eliminated the faults proceed to “Check the Signal for the Throttle Position Sensor ”.

Check the Signal for the Throttle Position Sensor

1. Use the electronic service tool and observe the

signal for the throttle position sensor.

2. If the signal is erratic, refer to Troubleshooting, “Throttle Position Sensor Circuit - Test”.

3. If the engine has a throttle switch refer to Troubleshooting, “Throttle Switch Circuit - Test”.

i01798114

2. Check for leaks in the oil cooler core. Refer to Testing and Adjusting, “Cooling System” for the correct procedure. If a leak is found, install a new oil cooler core. Refer to Disassembly and Assembly, “Engine Oil Cooler - Remove” for the correct procedure. Fit new seals between the oil cooler and the oil cooler cover.

3. Remove the oil filter element or elements. Fit a new engine oil filter element or elements. Fill the crankcase with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual, “Engine Oil and Filter - Change” for more information.

Cylinder Head Gasket

1. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove” for the correct procedure.

2. Inspect the cylinder head gasket for faults and any signs of leakage.

3. Check the cylinder liner projection. Refer to Testing and Adjusting, “Basic Block” for more information. Correct the cylinder liner projection if it is incorrect.

4. If all of the cylinder liner projections were correct, and if there was no obvious signs of a faulty head gasket proceed to the recommended actions for the Cylinder Head.

Coolant in Engine Oil

Note: This is NOT an electronic system problem.

Refer to Testing and Adjusting for information on determining the cause of this condition.

Probable Causes

Engine oil cooler core

•

Cylinder head gasket

•

Cylinder head

•

Cylinder block

•

Recommended Actions

Engine Oil Cooler Core

1. Drain the engine lubricating oil from the engine.

5. If any of the cylinder liner projections were

incorrect, and this had resulted in the failure of the head gasket, fit a new head gasket.

6. To fit a new cylinder head gasket, refer to Disassembly and Assembly, “Cylinder Head Install” for the correct procedure.

Cylinder Head

Check the cylinder head for flatness. Refer to Systems Operation, “Cylinder Head - Inspect” for the correct procedure.

Check for cracks in the cylinder head. If a crack is found, repair the cylinder head and/or replace the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head - Install” for the correct procedure.

If the cylinder head is flat and if the cylinder head is not cracked then refer to the recommended actions for the Cylinder Block.

Troubleshooting Section

Cylinder Block

Inspect the cylinder block for cracks. If a crack is found, repair the cylinder block or replace the cylinder block.

i01798115

Coolant Temperature Is Too High

Note: This is not an electronic system problem.

Refer to Testing and Adjusting for information on determining the cause of this condition.

Probable Causes

Radiator fins

•

Coolant level

•

Radiator cap and/or pressure relief valve

•

Combustion gases in the cooling system

•

Engine cooling fan

•

Water temperature regulators

•

Restriction in the coolant system

•

Coolant temperature gauge

•

Coolant pump

•

Excessive load on the system

•

Radiator Cap and/or Pressure Relief Valve

1. Pressure test the cooling system. Refer to Testing

and Adjusting, “Cooling System” for the correct procedure.

2. Check operation of the pressure relief valve and the radiator cap. If necessary, clean the components and/or replace the components.

3. Check that the seating surfaces of the pressure relief valve and the radiator cap are clean and undamaged.

Combustion Gases in the Cooling System

Switch off the engine and allow the engine to cool to below normal working temperature. Remove the pressure cap for the coolant system. Start the engine and inspect the coolant for the presence of bubbles. If bubbles are present in the coolant, combustion gases may be entering the cooling system. Check the cylinder head gasket. Refer to the recommended action for the cylinder head gasket within Troubleshooting, “Coolant in Engine Oil”. Check the cylinder head for flatness. Refer to the recommended action for checking flatness of the cylinder head within Systems Operations, “Cylinder Head - Inspect”. Fit the pressure cap if there are no bubbles in the coolant.

Water Temperature Regulator

Check the water temperature regulator for correct operation. Refer to Testing and Adjusting, “Cooling System” for the proper procedure. If necessary, replace the water temperature regulator. Refer to Disassembly and Assembly, “Water Temperature Regulator - Remove and Install” for more information.

Recommended Actions

Radiator Fins

Check the radiator fins for dirt, debris, and/or damage. Remove any dirt and/or debris and straighten any bent fins.

Coolant Level

1. Inspect the coolant level. If necessary, add

coolant.

2. Check the cooling system for leaks. Repair any leaks immediately.

Restriction in the Coolant System

1. Visually inspect the cooling system for collapsed

hoses and/or other restrictions.

2. Clean the radiator and flush the radiator. Refer to Testing and Adjusting, “Cooling System”.

Coolant Temperature Gauge

Compare the reading for the coolant temperature from the electronic service tool to the reading for the coolant temperature from a mechanical gauge.

Coolant Pump

Inspect the impeller of the coolant pump for damage and/or erosion. If necessary, repair the coolant pump or replace the coolant pump.

38 Troubleshooting Section

Excessive Load on the System

Reduce the load and verify that the condition does not reoccur.

i01798116

ECM Will Not Accept Factory Passwords

Probable Causes

Passwords

•

Serial Numbers

•

Total Tattletale

•

Reason Code

•

Recommended Actions

1. Verify that the correct passwords were entered.

Check every character in each password. Turn the keyswitch to the OFF position for 30 seconds and then retry.

2. Verify that the electronic service tool is on the “Factory Password” screen.

3. Use the electronic service tool to verify that the following information has been entered correctly:

Electrical connectors

•

Data Link

•

Recommended Actions

1. Connect the electronic service tool to the

service tool connector. If the ECM does not communicate with the electronic service tool, refer to Troubleshooting, “Electronic Service Tool Will Not Communicate with ECM”.

2. Ensure that the following items are correctly installed and undamaged. Refer to Troubleshooting, “Electrical Connectors Inspect”.

J1/P1 ECM connector

•

J20/P20 Machine interface connector

•

Wiring to display modules

•

Wiring to other control modules

•

3. Troubleshoot the Data Link for possible problems. Refer to Troubleshooting, “Data Link Circuit Test”.

i01798118

Electronic Service Tool Will Not Communicate with ECM

Engine serial number

•

ECM serial number

•

Serial number for the electronic service tool

•

Total tattletale

•

Reason code

•

i01798117

ECM Will Not Communicate with Other Systems or Display Modules

Probable Causes

ECM

•

Probable Causes

The electronic service tool is not correctly

•

configured.

The cables to the electronic service tool are not

•

connected correctly.

The electronic service is not functioning.

•

The electrical power supply to the electronic

•

service tool

The engine protection device is disabling the

•

power supply.

The electrical power supply to the ECM

•

The engine harness

•

Battery voltage

•

Troubleshooting Section

Recommended Actions

Connect the communication adapter of the electronic service tool to the PC and to the diagnostic connector. Turn the ignition switch to the ON position. If the communication adapter for the electronic service tool activates, and the red power indicator lamp is ON, proceed to step 3. If the red power indicator lamp remains OFF proceed to step 1.

1. Check the battery voltage to the Data Link Connector. Refer to Troubleshooting, “Data Link Circuit - Test, Test Step 4”.

2. Change the electronic service tool components. Refer to Troubleshooting, “Data Link Circuit Test, Test Step 6”.

3. Start the program for the electronic service tool. If the electronic service tool reports “Connected and 1 (or more) module detected” then STOP. If the electronic service tool reports “The interface hardware is not connected” then proceed to step

4. If the electronic service tool cannot connect to the ECM then proceed to step 5.

4. Inspect the cable from the PC to the communication adapter. Verify that the correct PC port has been used. Inspect the cable from the electronic service tool to the diagnostic connector. Change the electronic service tool components. Refer to Troubleshooting, “Data Link Circuit - Test, Test Step 6”.

5. Check the battery voltage at the ECM if the electronic service tool cannot connect to the ECM. Refer to Troubleshooting, “Data Link Circuit

- Test, Test Step 3”.

Starting motor or starting circuit

•

Valve lash

•

Fuel injection nozzle

•

Air inlet heater starting aid

•

Air intake and exhaust system

•

Low compression (cylinder pressure)

•

Fuel supply

•

Recommended Actions

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

Visual Checks

1. Visually inspect the engine for the following

faults:

Missing components

•

Damaged components

•

Oil leaks

•

Coolant leaks

•

Fuel leaks

•

Hydraulic leaks

•

6. Connect the electronic service tool directly to the ECM and follow the test procedure as Troubleshooting, “Data Link Circuit - Test, Test Step 5”.

7. Connect the electronic service tool and the ECM to another battery. Proceed to Troubleshooting, “Data Link Circuit - Test, Test Step 7”.

i01798119

Engine Cranks but Will Not Start

Probable Causes

Refer to the logged codes.

•

Crank without injection (if equipped)

•

Check electrical cables for damage. Check

•

that the electrical cables are properly secured.

Check for the proper level of fuel, oil, coolant,

•

and hydraulic fluids

2. Try to start the engine. If the engine does not start, verify that the crankshaft is rotating. Use a suitable hand tool in order to rotate the crankshaft.

3. If the crankshaft rotates freely proceed to “Starting Motor Solenoid or Starting Circuit”.

4. If the crankshaft does not rotate freely, check the engine for the following problems:

Seized piston

•

Defects in the drive gears

•

Fluid in the cylinder bores

•

40 Troubleshooting Section

Improper timing of valves

•

Crank Without Injection (If Equipped)

1. Check if the crank without injection plug is

connected.

2. If the crank without injection plug has been connected, connect the normal running plug.

3. Check if the engine will start.

4. If the repairs do not eliminate the problem refer

to Troubleshooting, “Crank without Inject Circuit

- Test”.

Starting Motor Solenoid or Starting Circuit

1. Turn the keyswitch to the OFF position.

2. Check the positive battery and negative battery

connections to the ECM.

3. Perform a pull test on positive battery wires and negative battery wires. Refer to Troubleshooting, “Electrical Connectors - Inspect”.

Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. If the repairs do not eliminate the problem proceed to “Air Inlet Heater Starting Aid”.

Air Inlet Heater Starting Aid

1. Check that the air inlet heater is receiving both an

electrical current and a supply of fuel. Check the operation of the air inlet heater starting aid. Refer to Systems Operation, “Air Inlet Heater - Test”.

2. If the repairs do not eliminate the problem proceed to “Air Intake and Exhaust System”.

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if

equipped.

4. Check the negative battery connection on the ground stud.

5. Check the connections of starting motor terminals.

6. Check the starting motor solenoid.

7. Remove the starting motor and check the starter

motor for proper operation. Check the pinion of the starting motor and check the flywheel ring gear.

8. Check the operation of the starting switch. Refer to Troubleshooting, “Electrical power Supply Circuit - Test”.

Valve lash

1. Check the valve lash and reset the valve lash

if it is necessary. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash Inspect and Adjust”.

Ensure that the repairs have eliminated the active diagnostic codes before attempting to restart the engine.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and exhaust systems for

the following defects:

Blockages

•

Restrictions

•

Damage to lines or hoses

•

4. Repair any defects before attempting to restart the engine.

5. If the engine will not start proceed to “Low Compression”.

Low Compression

1. Remove the fuel nozzles and perform a

compression test. Refer to Systems Operations, Testing and Adjusting, “Compression - Test ”data.

Examples of low compression are shown in the following list:

Outside temperatures are too cold.

•

If the engine will not start proceed to “Air Intake and Exhaust System”.

Mechanical problem

•

Faulty piston rings

•

Troubleshooting Section

Worn cylinder bores

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the active

diagnostic code.

4. If the engine will not start proceed to “Fuel Supply”.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

Leaks in air intake system

•

Low oil pressure

•

Recommended Actions

Dirt in Engine Oil

1. Drain the oil from the crankcase and refill the

crankcase with clean engine oil. Install new engine oil filters. Refer to the Operation and Maintenance Manual for more information.

2. Check the oil filter bypass valve for a weak spring or a broken spring. If the spring is weak or broken, replace the spring. Refer to Disassembly and Assembly, “Engine Oil Filter Base” for more information.

Leaks in Air Intake System

A leak in the air intake system may allow unfiltered air into the engine. Inspect the air intake system for leaks. Inspect all of the gaskets and the connections. Repair any leaks. Refer to Testing and Adjusting, “Air Intake System” for more information.

Low Oil Pressure

4. Check for air in the fuel system. Refer to Systems

Operation, Testing and Adjusting, “Air in Fuel Test”.

5. Check that the fuel lines are tight and secured properly.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).



C (32F), check

i01798120

Engine Has Early Wear

Refer to Troubleshooting, “Low Engine Oil Pressure” for the testing procedure. Repair any identified faults.

i01798121

Engine Misfires, Runs Rough or Is Unstable

The probable root causes are listed in order below:

Note: If the problem is intermittent and the problem cannot be duplicated, refer to Troubleshooting, “Intermittent Low Power or Power Cutout”.

Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high rpm, full load and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results.

Probable Causes

Dirt in engine oil

•

Refer to the logged codes.

•

Fuel supply

•

Air intake and exhaust system

•

42 Troubleshooting Section

Individual malfunctioning cylinder

•

Valve lash

•

Low compression (cylinder pressure)

•

Fuel injection nozzles

•

Air inlet heater starting aid

•

Engine speed/timing sensors

•

Throttle position sensor

•

Fuel injection pump

•

Recommended Actions

Logged Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

12. If the repairs do not eliminate the problem proceed to “Air Intake and Exhaust System”.

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if

equipped.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and exhaust systems for

the following defects:

Blockages

•

Restrictions

•

Damage to lines or hoses

•

4. If the repairs do not eliminate the problem proceed to “Individual Malfunctioning Cylinders”.

Individual Malfunctioning Cylinders

1. With the engine speed at a fast idle, loosen

the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.

2. Individually repeat this procedure for each fuel injection nozzle. If there is not a reduction in the engine speed proceed to “Check the Air Inlet Heater Starting Aid”.

3. If there is a reduction in engine speed proceed to “Valve Lash”.

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”.

5. Check that the fuel lines are tight and secured properly.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).



C (32F), check

Valve lash

1. Check the valve lash and reset the valve lash

if it is necessary. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash Inspect and Adjust”.

2. If the repair does not eliminate the fault proceed to “Check for Low Compression”.

Check for Low Compression

Examples of low compression are shown on the following list:

Mechanical problems

•

Faulty piston rings

•

Worn cylinder bores

•

Worn valves

•

Troubleshooting Section

Faulty cylinder head gasket

•

Damaged cylinder head

•

1. Remove the fuel injection nozzles and perform a compression test. Refer to Systems Operations, Testing and Adjusting, “Compression - Test ” data.

2. Make all necessary repairs to the engine.

3. If the repair does not eliminate the fault proceed

to “Check the Fuel Injection Nozzles”.

Check the Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. If the repairs do not eliminate the fault proceed to “Check the Air Inlet Heater Starting Aid”.

Check the Air Inlet Heater Starting Aid

1. Check for proper operation of the air inlet heater

starting aid. Refer to Systems Operation, Testing and Adjusting, “Electrical System”.

2. If the repairs do not eliminate the fault refer to “Check the Engine Speed/Timing Sensors”.

4. If a fault with the engine speed/timing sensor is suspected refer to Troubleshooting, “Engine Speed/Timing Circuit - Test”.

5. If a fault with the engine speed/timing sensor is not suspected proceed to “Check the Signal for the Throttle Demand Sensor”.

Check the Signal for the Throttle Position Sensor

1. Use the electronic service tool and observe the

signal for the throttle position sensor.

2. If the signal is erratic, refer to Troubleshooting, “Throttle Position Sensor Circuit - Test”.

3. If the engine has a 10 position throttle switch refer to Troubleshooting, “Throttle Switch Circuit

- Test”.

4. If the repairs do not eliminate the fault proceed to “Check the Fuel injection Pump”.

Check the Fuel Injection Pump

Note: The fuel injection pumps that are installed by the factory on the 1100 series engines are nonserviceable items. If any mechanical fault or any electrical fault occurs within the fuel injection pump then the fuel injection pump must be replaced.

1. Use the electronic service tool to select the correct screen display. Refer to Troubleshooting, “Troubleshooting with a Diagnostic Code”.

Check the Engine Speed/Timing Sensors

Note: There are two engine speed/timing sensors. One sensor is positioned in the cylinder block in order to sense the crankshaft position and the crankshaft speed. The other sensor is in the fuel injection pump in order to sense the pump’s internal timing wheel and speed. The sensor in the fuel injection pump is not serviceable. If the sensor in the fuel injection pump is faulty then the fuel injection pump should be replaced.

1. Ensure that the engine speed/timing sensor is installed correctly to the cylinder block.

2. Ensure that the connectors and cables for the engine speed/timing sensors are connected correctly.

3. Check the wiring harness in order to ensure that the cables to the sensors are not too tight. This could cause an intermittent problem due to vibration.

2. If the problem is not eliminated, check for active diagnostic fault codes.

3. Refer to Troubleshooting, “Fuel Injection Pump Circuit - Test”.

i01798122

Engine Oil in Cooling System

Note: This is NOT an electronic system problem.

Refer to Testing and Adjusting for information on determining the cause of this condition.

Probable Causes

Engine oil cooler core

•

Cylinder head gasket

•

Cylinder head

•

44 Troubleshooting Section

Recommended Actions

Engine Oil Cooler Core

1. Drain the coolant from the engine and the

radiator. Drain the lubricating engine oil from the engine oil cooler. Refer to the Operation and Maintenance Manual for more information.

2. Inspect the engine oil cooler core for leaks. Refer to Testing and Adjusting, “Cooling System” for the correct procedure. If a leak is found, replace the oil cooler core. Refer to Disassembly and Assembly, “Engine Oil Cooler Core - Remove”. Fit new seals between the oil cooler and the oil cooler cover.

3. Refill the crankcase with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual for more information.

Cylinder Head Gasket

1. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove” for the correct procedure.

Thoroughly flush the coolant system in order to remove all traces of the engine lubricating oil from the coolant system. Fill the coolant system with coolant. Refer to Operation and Maintenance Manual for more information.

i01798123

Engine Speed Does Not Change

Note: Use this procedure only if the engine speed does not change.

Probable Causes

Refer to logged codes.

•

Throttle switch

•

Throttle position sensor

•

Engine speed/timing sensor

•

2. Inspect the cylinder head gasket for faults and any signs of leakage.

3. Check the cylinder liner projection. Refer to Testing and Adjusting, “Basic Block” for the correct procedure.

4. If all of the cylinder liner projections were correct, and if there was no obvious signs of a faulty head gasket proceed to the recommended actions for the Cylinder Head.

5. If any of the cylinder liner projections were incorrect, and this had resulted in the failure of the head gasket, fit a new head gasket. Refer to Disassembly and Assembly, “Cylinder Head Install” for the correct procedure.

Cylinder Head

1. Check the cylinder head for flatness. Refer to

Systems Operation, “Cylinder Head - Inspect” for the correct procedure.

2. Check the cylinder head for cracks. If a crack is found, repair the cylinder head and/or replace the cylinder head. If the cylinder head is not cracked and the head is flat, fit the head. Refer to Disassembly and Assembly, “Cylinder Head Install” for the correct procedure.

Recommended Repairs

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

If a problem with the throttle switch is suspected refer to Troubleshooting, “Throttle Switch Circuit Test”.

Refer to Troubleshooting, “Throttle Position Sensor Circuit - Test” if any of the following diagnostic codes are active.

91-08 Throttle Position Sensor Abnormal

•

774-08 Sec Throttle Position Signal Abnormal

•

41-03 8 Volt Sensor Power Supply Voltage more

•

than normal

41-04 8 Volt Sensor Power Supply Volltage less

•

than normal

Refer to Troubleshooting, “Engine Speed/Timing Sensor Circuit - Test” if any of the following diagnostic codes are active.

320-02 Speed/Timing Sensor intermittent loss of

•

signal

Troubleshooting Section

320-11 Speed/Timing Sensor loss of signal

•

If there are no active diagnostic codes refer to the Troubleshooting Manual for your machine application.

i01798124

Engine Stalls at Low RPM

Probable Causes

Refer to logged codes.

•

Faulty fuel injection nozzles

•

Fuel supply

•

Accessory equipment

•

Power mode control (if equipped)

•

Recommended Actions

5. Check that the fuel lines are tight and secured

properly.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).

NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.



C (32



F), check

Accessory Equipment

Diagnostic Codes

Check for active diagnostic codes on the Electronic Service Tool. Troubleshoot any active codes before continuing with this procedure.

Fuel Injection Nozzles

1. Check for correct installation of fuel injection

nozzles. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Install”.

2. Check for proper operation of the fuel injection nozzle. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Nozzle - Test”.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

Check all accessory equipment for problems that may create excessive load on the engine. Repair any damaged components or replace any damaged components.

Power Mode Control (If Equipped)

1. Check the Data Link. Refer to Troubleshooting, “

Data Link Circuit - Test”.

2. Check the engine wiring harness for defects. Refer to Troubleshooting, “Electricial Connectors

- Inspect”.

3. If there are no active diagnostic codes refer to the Troubleshooting Manual for your engine application.

i01798125

Engine Vibration

Note: This is NOT an electronic system problem.

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”.

Refer to Testing and Adjusting for information on determining the cause of this condition.

Probable Causes

Engine supports

•

Malfunctioning individual cylinder

•

46 Troubleshooting Section

Valve lash

•

Compression (cylinder pressure)

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

Recommended Actions

Engine Supports

1. Start the engine and run the engine through the

speed range. Check for any of the following conditions:

Loose engine supports

•

Loose mounting brackets or broken mounting

•

brackets

Loose bolts

•

Omitted bolts

•

2. Make all necessary repairs. Ensure that the repairs have eliminated the problem. If the vibration is still present proceed to “Malfunctioning Individual Cylinder”.

Malfunctioning Individual Cylinder

1. With the engine speed at a fast idle, loosen

the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.

2. Individually repeat this procedure for each fuel injection nozzle. If there is no reduction in the engine speed proceed to “Check The Fuel Injection Nozzles”.

3. If there is a reduction in engine speed proceed to “Valve Lash”.

Valve Lash

1. Ensure that the valve lash is correct. Reset the

valve lash if it is not correct. Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect and Adjust”.

2. If the repair does not eliminate the fault proceed to “Check for Low Compression (cylinder pressure)”.

Check for Low Compression (cylinder pressure)

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. Perform a compression test on each cylinder. Refer to Systems Operation, Testing and Adjusting, “Compression - Test”.

4. Ensure that the repairs have eliminated the problems.

5. If the problem has not been eliminated, proceed to “Check the Fuel Injection Nozzles”.

Check the Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Turbocharger (if equipped)”.

Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable items. If any mechanical fault exists then the turbocharger must be replaced.

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the turbocharger drain is not blocked or restricted.

3. Check that the turbocharger housing is free of dirt and debris.

4. Check the turbocharger for worn bearings. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The turbochargers that are equipped on 1100 Series engines are not serviceable. If any mechanical fault exists then the turbocharger must be replaced.

Troubleshooting Section

5. Check that the turbine blades of the turbocharger rotate freely. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The adjustment of the wastegate is set at the factory. If the adjustment of the wastegate is incorrect then the turbocharger must be replaced.

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

i01798126

Engine Will Not Crank

Probable Causes

Machine security system

•

6. If there are no active diagnostic codes refer to the Troubleshooting Manual for your machine application.

Battery Cables and/or Batteries

1. Inspect the main power switch, battery posts,

and battery cables for loose connections and corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Clean the battery posts. Replace the cables. Tighten any loose connections.

2. Inspect the batteries.

a. Charge the batteries.

b. Load test the batteries.

Starting Motor Solenoid or Starting Circuit

1. Test the operation of the starting motor solenoid.

Refer to Systems Operation/Testing and Adjusting, “Starting System”.

Battery cables and/or batteries

•

Starting motor solenoid or starting circuit

•

Starting motor and/or flywheel ring gear

•

Electrical power supply

•

Internal engine problem

•

Recommended Repairs

Machine Security System

1. Verify that the correct keyswitch is being used.

Turn the keyswitch to the ON position.

2. Use the electronic service tool in order to check if the 1639-09 Machine Security System is active. Verify that the lamp for the machine security system is on.

3. If the 1639-09 diagnostic code is active the machine security system is armed. Deactivate the machine security system and try to start the engine.

2. Check the wiring to the starting motor solenoid.

Starting Motor and/or Flywheel Ring Gear

1. Test the operation of the starting motor. Check

the wiring for the starting motor. Refer to System Operation, “System Starting”.

2. Inspect the starter motor pinion and the flywheel ring gear for damage.

Electrical Power Supply

Check the electrical power supply. Refer to Troubleshooting, “Electrical Power Supply Circuit Test”.

Internal Engine Problem

1. Disassemble the engine. Refer to Disassembly

and Assembly.

2. Inspect the internal components for the following conditions:

Seizure

•

4. If the engine will not start use the electronic service tool to check for logged diagnostic codes.

5. Make repairs for all diagnostic codes. Ensure that the repair has eliminated the problem.

Broken components

•

Bent components

•

48 Troubleshooting Section

i01798127

Excessive Black Smoke

Probable Causes

Air intake system or exhaust system

•

Individual malfunctioning cylinder

•

Valve lash

•

Low compression (cylinder pressure)

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

Broken 5 volt supply wire to the pressure sensor

•

in the intake manifold

ECM software

•

Recommended Actions

Air Intake System or Exhaust System

1. Check the air filter restriction indicator, if

equipped.

2. Individually repeat this procedure for each fuel injection nozzle. If there is no reduction in the engine speed proceed to “Checking the Fuel Injection Nozzles”.

3. If there is a reduction in engine speed proceed to “Valve Lash”.

Valve Lash

Ensure that the valve lash is correct. Reset the valve lash if it is not correct. Refer to Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust”.

If the repair does not eliminate the fault proceed to “Low Compression (cylinder pressure)”.

Low Compression (cylinder pressure)

Examples of low compression are shown in the following list:

Mechanical problem

•

Faulty piston rings

•

Worn cylinder bores

•

Worn valves

•

Faulty cylinder head gasket

•

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and the exhaust system for

the following defects:

Blockages

•

Restrictions

•

Damage to the air intake and exhaust lines

•

and hoses

4. Make all necessary repairs to the engine.

5. If the problem has not been eliminated, proceed

to “Individual Malfunctioning Cylinder”.

Individual Malfunctioning Cylinder

1. With the engine speed at a fast idle, loosen

the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.

Damaged cylinder head

•

1. Remove the fuel injection nozzles and perform a compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data.

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the faults.

4. If the repair does not eliminate the fault proceed

to “Checking the Fuel Injection Nozzles”.

Checking the Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Check the Turbocharger (if equipped)”.

Troubleshooting Section

Check the Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable items. If any mechanical fault exists then the turbocharger must be replaced.

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the turbocharger drain is not blocked or restricted.

3. Check that the turbocharger housing is free of dirt and debris.

5. Check that the turbine blades rotate freely on the turbocharger. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The adjustment of the wastegate is set by the factory. If the adjustment of the wastegate is incorrect then the turbocharger must be replaced.

7. Make all necessary repairs to the engine.

2. Use the electronic service tool to verify any

active diagnostic codes.

3. If diagnostic codes are present, the ECM must be programmed with the correct information.

i01798128

Excessive Engine Oil Consumption

Probable Causes

Oil level

•

Engine crankcase breather

•

Engine oil temperature

•

Air intake and exhaust system

•

Turbocharger (if equipped)

•

Low compression (cylinder pressure)

•

Recommended Actions

Oil Level

Remove excess oil. Locate the source of the excess fluid. Repair the leaks that are causing the problems. Recheck all fluid levels.

8. Ensure that the repairs have eliminated the faults.

9. If the repairs have not eliminated the fault

proceed to “Broken 5 volt supply wire”.

Broken 5 volt Supply Wire

1. Check the 5 volt supply for the intake manifold

pressure sensor. Refer to Troubleshooting, “5 volt Pressue Sensor Supply Circuit - Test”.

2. If the repairs have not eliminated the fault proceed to “Verifying the ECM Software”.

Verifying the ECM Software

1. Connect the electronic service tool to the

diagnostic connector and check for the following conditions:

Check for the correct engine serial number

•

Check for the correct arrangement number

•

Check for the correct software

•

Engine Crankcase Breather

1. Check the engine crankcase breather (if

equipped) for blockage or restrictions.

2. Repair all defects. Verify that the repair has eliminated the problem.

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if

equipped.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and the exhaust system for

the following defects:

Blockages

•

Restrictions

•

Damage to the air intake and exhaust lines

•

and hoses

50 Troubleshooting Section

4. Make all necessary repairs to the engine.

5. Ensure that the repairs have eliminated the

diagnostic code.

Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable. If any mechanical fault exists then the turbocharger must be replaced.

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the turbocharger drain is not blocked or restricted.

3. Check that the turbocharger housing is free of dirt and debris.

4. Check the turbocharger for worn bearings. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The turbochargers that are equipped on 1100 series engines are not serviceable. If any mechanical fault exists then the turbocharger should be replaced.

5. Check that the turbine blades rotate freely on the turbocharger. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

Mechanical problem

•

Faulty piston rings

•

Worn cylinder bores

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

4. Inspect the internal engine components. Replace any worn components.

i01798129

Excessive Valve Lash

Note: This is NOT an electronic system problem.

Refer to Testing and Adjusting for information on determining the cause of this condition.

Probable Causes

Lubrication

•

Valve lash

•

Valve train components

•

Recommended Actions

Lubrication

1. Remove the valve mechanism covers. Refer to

Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure.

Low Compression (cylinder pressure)

1. Verify that the valve lash is correct. Refer

to Systems Operation, “Engine Valve Lash Inspect/Adjust”.

1. Remove the fuel injection nozzles and perform a compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data.

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the faults.

Examples of low compression are shown in the following list:

2. Check the lubrication in the valve compartment. Ensure that there is adequate engine oil flow in the valve compartment. The passages for the engine oil must be clean.

Valve Lash

Adjust the valve lash of the engine. Refer to Testing and Adjusting, “Air Intake and Exhaust System” for the correct procedure.

Valve Train Components

1. Inspect the following components of the valve

train:

Troubleshooting Section

Rocker arms

•

Pushrods

•

Valve lifters

•

Camshaft

•

Valve stems

•

Rocker shafts

•

2. Check the components for the following conditions: abnormal wear, excessive wear, straightness, and cleanliness. If necessary, use new parts for replacement.

Note: If the camshaft is replaced, new valve lifters must also be used.

3. Adjust the valve lash of the engine. Refer to Testing and Adjusting, “Engine Valve Lash Inspect/Adjust” for the correct procedure.

i01798130

Excessive White Smoke

Note: Some white smoke may be present during cold start-up conditions when the engine is operating normally. If the white smoke persists, there may be a problem.

Probable Causes

Fuel supply

•

Individual malfunctioning cylinder

•

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”.

5. Check that the fuel lines are tight and secured properly.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).



C (32



F), check

Individual Malfunctioning Cylinder

1. With the engine speed at a fast idle, loosen

the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.

2. Individually repeat this procedure for each fuel injection nozzle.

Valve lash

•

Low compression (cylinder pressure)

•

Air inlet heater starting aid

•

Fuel injection nozzles

•

Coolant temperature sensor circuit

•

Engine pressure sensors

•

Recommended Actions

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

3. If there is no reduction in the engine speed proceed to “Fuel Injection Nozzles”.

4. If there is a reduction in engine speed proceed to “Valve Lash”.

Valve Lash

1. Ensure that the valve lash is correct. Refer to

Testing and Adjusting, “Engine Valve Lash Inspect/Adjust”. Rest the valve lash if it is not correct.

2. If the repair does not eliminate the fault proceed to “Low Compression (cylinder pressure)”.

52 Troubleshooting Section

Low Compression (cylinder pressure)

1. Remove the fuel injection nozzles and perform a

compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data.

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the faults.

Examples of low compression are shown in the following list:

Mechanical problem

•

Faulty piston rings

•

Worn cylinder bores

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

4. If the repair does not eliminate the fault proceed to “Air Inlet Heater Starting Aid”.

2. Monitor the display screen on the electronic service tool in order to verify the presence of active diagnostic codes for the coolant temperature. Refer to Troubleshooting, “Engine Temperature Sensor Open or Short Circuit - Test”.

Engine Pressure Sensors

1. Connect the electronic service tool to the

diagnostic connector.

2. Monitor the display screen on the electronic service tool in order to verify the presence of active diagnostic codes for the engine pressure sensors. Refer to Troubleshooting, “5 Volt Engine Pressure Sensor Supply Circuit - Test”.

i01798131

Intake Air Temperature Is Too High

Probable Causes

Air Inlet Heater Starting Aid

1. Verify that the air inlet heater is operating

correctly. Refer to Testing and Adjusting, “Air Inlet Heater - Test”.

2. If the repair does not eliminate the fault proceed to “Fuel Injection Nozzles”.

Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Coolant Temperature Sensor Circuit”.

Coolant Temperature Sensor Circuit

1. Connect the electronic service tool to the

diagnostic connector.

High ambient air temperature

•

High coolant temperature

•

High intake air restriction and/or high altitude

•

Faulty intake manifold air temperature sensor

•

and/or circuit

Insufficient flow of cooling water through the

•

aftercooler (if equipped)

Insufficient flow of air through the aftercooler (if

•

equipped)

Recommended Repairs

High Ambient Air Temperature

Determine if the ambient air temperature is within the design specifications for the cooling system.

Determine the cause of the high air temperature. Make corrections, when possible.

Coolant Temperature

Refer to Troubleshooting, “Coolant Temperature Is Too High”.

Troubleshooting Section

Check for High Intake Air Restriction and/or High Altitude

When intake air pressure is low, the turbocharger (if equipped) works harder in order to achieve the desired intake manifold pressure. This increases intake air temperature.

Measure the intake manifold pressure while the engine is operating under load. For specific data, refer to the Technical Marketing Information for the engine.

Intake Air Restriction

Check for plugged air filters. Check for obstructions to the air intake.

Replace the air filters and/or remove the obstruction from the air intake.

High Altitude

Make sure that the settings for the engine are correct for the altitude.

Check the Intake Manifold Air Temperature Sensor and/or the Circuit

Check for Sufficient Flow of Air Through the Aftercooler (if equipped)

Determine the pressure differential of the intake air across the aftercooler. For specific data, refer to the Technical Marketing Information for the engine.

If the pressure differential of the air across the aftercooler does not match the specifications, clean the aftercooler.

i01798132

Intermittent Engine Shutdown

Note: Use this procedure only if the engine shuts down completely and the engine must be restarted.

Probable Causes

Refer to the logged codes.

•

Fuel supply

•

Engine protection device (if equipped)

•

Electrical connectors

•

Allow the intake manifold air temperature sensor to cool and remove the sensor. Check the reading for the intake air temperature. If the sensor is OK, the reading and the ambient temperature are approximately equal.

If the reading is not correct, replace the sensor with a sensor that is known to be good. Verify that the problem is solved.

Check for Sufficient Coolant Flow Through the Aftercooler (if equipped)

Check the intake temperature of the coolant for the aftercooler. Compare the reading to the regulated temperature. If the temperature is OK, check the outlet temperature of the coolant. A high temperature differential indicates an insufficient flow rate.

If there is a high differential between the intake temperature and the outlet temperature of the coolant for the aftercooler, perform the following procedures:

Check the coolant circuit of the aftercooler for

•

obstructions.

Check the pump for proper operation.

•

Make repairs, if necessary.

•

Recommended Actions

Logged Codes

Check for any event and active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

Fuel Supply

NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

2. Ensure that the fuel system has been primed.

Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

3. Check the diesel fuel for contamination. Refer to

Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

4. Check for air in the fuel system. Refer to Systems

Operation, Testing and Adjusting, “Air in Fuel Test”.

54 Troubleshooting Section

5. Check that the fuel lines are tight and secured properly.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).



C (32



F), check

Engine Protection Device (if equipped)

1. Check if a warning lamp is ON.

2. Refer to Troubleshooting, “Indicator Lamp Circuit

- Test”.

3. Repair any faults and ensure that the engine protection device is not in operation.

3. Use the electronic service tool to check for the following logged diagnostic code: 253-02 “Incorrect ECM Software”. If this diagnostic code is logged, proceed to Troubleshooting, “Electrical Power Supply Circuit - Test”.

4. Inspect the battery wires from the ECM back to the battery compartment. Refer to the Engine Wiring Diagram. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refer to Troubleshooting, “Fuel Injection Pump Circuit Test” for more information.

5. Check the P40 VP30 fuel pump connector. Refer to Troubleshooting, “Fuel Injection Pump Circuit

- Test”.

6. Repair any faults and ensure that the faults have been eliminated.

i01798133

Intermittent Low Power or Power Cutout

4. If the fault has not been eliminated refer to

“Electrical Connectors”.

Electrical Connectors

1. Check for correct installation of ECM connectors

at the following locations:,

J1/P1 ECM connector

•

J20/P20 Machine interface connector

•

J401/P401 Speed/timing sensor connector

•

J100/P100 Intake manifold air temperature

•

sensor connector

J103/P103 Engine coolant temperature sensor

•

connector

J201/P201 Engine oil pressue sensor

•

connector

J200/P200 Intake manifold pressure sensor

•

connector

P40 Fuel injection pump connector

•

Note: Use this procedure only if the engine does not shut down completely.

Probable Causes

Refer to the logged codes.

•

Electrical connectors

•

Fuel supply

•

Intake manifold pressure

•

Air intake and exhaust system

•

ECM connection

•

Throttle position sensor

•

Recommended Repairs

NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

2. Refer to Troubleshooting, “Electrical Connectors

- Inspect”.

Troubleshooting Section

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

Electrical Connectors

1. Refer to Troubleshooting, “Electrical Connectors

- Inspect”.

2. Repair the electrical connectors or replace the electrical connectors.

3. Ensure that all the connector seals are in place and that the connectors have been correctly installed.

4. Ensure that the repairs have eliminated the fault. If the fault has not been eliminated proceed to “Fuel Supply”.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

Check the Intake Manifold Pressure

1. Use the electronic service tool to verify the intake

manifold pressure.

2. Turn the start switch to the ON position.

3. Check the intake manifold pressure. The

pressure should read 0 kPa (0 Psi).

4. Use the electronic service tool to check for the following logged diagnostic codes:

102-03 Intake Manifold Pressure Sensor open

•

circuit or shorted high

102-04 Intake Manifold Pressure Sensor

•

shorted low

If either of these diagnostic codes are logged, proceed to Troubleshooting, “Engine Pressure Sensor Open or Short Circuit - Test”.

5. If no faults are found proceed to “Air Intake and Exhaust System”.

Air Intake and Exhaust System

2. Ensure that the fuel system has been primed.

Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”.

5. Check that the fuel lines are tight and secured properly.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

1. Check the air filter restriction indicator, if equipped.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and exhaust systems for

the following defects:

Blockages

•

Restrictions

•

Damage to the air intake and exhaust lines

•

and hoses

4. Make all necessary repairs to the engine.

5. Ensure that the repairs have eliminated the

diagnostic code.

6. If the problem has not been eliminated, proceed to “ECM Connection”.

ECM Connection

1. Check that the J1/P1 connector is correctly

connected.

11. If the temperature is below 0 for solidified fuel (wax).



C (32F), check

2. Verify the proper pin positions for the power connections and the ground connections for the Engine Control Module (ECM).

56 Troubleshooting Section

3. If a problem is suspected with the ECM power and ground connections refer to Troubleshooting, “Electrical Power Supply Circuit - Test”.

4. Verify that the ECM connections for the power and ground connections at the fuel pump are connected properly.

5. If a fault is suspected with the fuel injection pump power and ground connections refer to Troubleshooting, “Fuel Injection Pump Circuit

- Test”.

6. Repair any faults and ensure that the faults have been eliminated.

7. If the repairs do not eliminate the faults, proceed to “Check the Throttle Position Sensor”.

Check the Throttle Position Sensor

1. Use the electronic service tool to observe the

throttle position status.

2. Operate the engine at a maximum no-load speed. Check that the throttle position (%) is inside calibration (80 to 87%) at high idle if the programmed limit for the upper demand cannot be obtained.

3. If the engine speed is erratic, reduce the engine speed.

4. Check that the calibration of the low idle is within 20 to 27%.

5. Slowly increase the engine speed. Check that the engine speed is steady. Check that the position increases with more throttle.

Engine oil pressure gauge

•

Engine oil bypass valves

•

Piston cooling jets (if equipped)

•

Engine oil suction tube

•

Engine oil pump

•

Bearing clearance

•

Recommended Actions

Engine Oil Level

Inspect the engine oil level. If necessary, add oil.

Engine Oil Pressure Gauge

Check the actual engine oil pressure with a mechanical gauge. Compare the oil pressure reading from the electronic service tool to the pressure on the mechanical gauge.

Engine Oil Bypass Valves

1. Remove the engine oil bypass valves and clean

the engine oil bypass valves. Clean the bores in the oil filter base for the bypass valves. Refer to Disassembly and Assembly, “Engine Oil Filter Base - Disassemble”.

2. Install new engine oil filters. Refer to the Operation and Maintenance Manual for more information.

Piston Cooling Jets (if equipped)

6. Refer to Troubleshooting, “Throttle Position Circuit

- Test”.

i01798134

Low Engine Oil Pressure

NOTICE Do not operate the engine with low oil pressure. Engine damage will result. If measured oil pressure is low, discontinue engine operation until the problem is corrected.

Probable Causes

Engine oil level

•

Inspect the piston cooling jets for damage. Replace any piston cooling jet that appears to be cracked or broken. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove and Install” for the correct procedure.

Engine Oil Suction Tube

1. Check the inlet screen on the oil suction tube

and remove any material that may be restricting oil flow.

2. Check the joints of the oil suction tube for cracks or a damaged O ring seal that may allow air leakage into the supply to the oil pump.

Troubleshooting Section

Engine Oil Pump

Inspect the components of the engine oil pump for excessive wear. Repair the oil pump or replace the oil pump, if necessary.

Bearing Clearance

Inspect the engine components for excessive bearing clearance. If necessary, replace the bearings and/or the components. The following list is an example of the components that should be inspected for excessive bearing clearance:

Crankshaft main bearings

•

Connecting rod bearings

•

Camshaft bearings

•

i01798135

Low Power/Poor or No Response to Throttle

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”.

5. Check that the fuel lines are tight and secured properly.

Probable Causes

Refer to logged codes.

•

Fuel supply

•

Air intake and exhaust system

•

Individual cylinder problem

•

Valve lash

•

Low compression (cylinder pressure)

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

ECM parameters

•

Electrical connectors

•

Recommended Actions

NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).

12. If the repairs do not eliminate the problem proceed to “Air Intake and Exhaust System”.



C (32



F), check

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if

equipped.

2. Ensure that the air filter is clean and serviceable.

3. Check the air intake and the exhaust system for

the following defects:

Blockages

•

Restrictions

•

Damage to the air intake and exhaust lines

•

and hoses

58 Troubleshooting Section

4. Make all necessary repairs to the engine.

5. Ensure that the repairs have eliminated the

diagnostic code.

6. If the problem has not been eliminated, proceed to “Individual Malfunctioning Cylinders”.

Individual Malfunctioning Cylinders

1. With the engine speed at a fast idle, loosen

the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.

2. Individually repeat this procedure for each fuel injection nozzle.

3. If there is no reduction in the engine speed proceed to “Checking the Fuel Injection Nozzles”.

4. If all cylinders have been checked and no problems were detected proceed to “Valve Lash”.

Faulty cylinder head gasket

•

Damaged cylinder head

•

Checking the Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Check the Turbocharger (if equipped)”.

Check the Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100 Series engines are nonserviceable items. If any mechanical fault exists then the turbocharger must be replaced.

Valve Lash

1. Check the valve lash and reset the valve lash, if

necessary. Refer to Systems Operation, Testing and Adjusting, “Engine Valve lash - Inspect and Adjust”.

2. If the repair does not eliminate the fault proceed to “Check for Low Compression”.

Check for Low Compression

1. Remove the fuel injection nozzles and perform a

compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test”.

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the faults.

4. If the repair does not eliminate the fault proceed

to “Checking the Fuel Injection Nozzles”.

Examples of low compression are shown in the following list:

Mechanical problem

•

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the turbocharger drain is not blocked or restricted.

3. Check that the turbocharger housing is free of dirt and debris.

4. Check the turbocharger for worn bearings. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The turbochargers that are equipped to 1100 series engines are not serviceable. If any mechanical fault exists then the turbocharger should be replaced.

5. Check that the turbine blades rotate freely on the turbocharger. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The adjustment to the wastegate is set at the factory. If the adjustment of the wastegate is incorrect then the turbocharger must be replaced.

Faulty piston rings

•

Worn cylinder bores

•

Worn valves

•

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

9. If the fault has not been eliminated proceed to

“ECM Parameters”.

Troubleshooting Section

ECM Parameters

1. Ensure that the problem is not a programmed

parameter.

2. Use the electronic service tool to ensure that the correct mode was selected.

3. Use the electronic service tool to verify that the correct engine rating has been provided.

4. Use the electronic service tool to verify the maximum engine speed limit.

5. Use the electronic service tool to reset the parameters to the OEM specifications.

6. Ensure that the repairs have eliminated the performance problems.

7. If the repairs have not eliminated the faults proceed to “Electronic System Problem”.

Electronic System Problem

1. Ensure that the correct mode is selected.

Valve train components

•

Connecting rod and main bearings

•

Recommended Actions

Accessory Equipment

Isolate the source of the noise. Remove the suspect engine accessories. Inspect the suspect engine accessories. Repair the engine accessories and/or replace the engine accessories if any defects are found.

Valve Train Components

Remove the valve mechanism covers. Check the following items for damage: camshaft, valve springs, lifters, pushrods, and bridges. Thoroughly clean the valve train components. If the camshaft is being replaced, also replace the valve lifters. Ensure that all of the valves move freely. Replace any damaged parts.

Connecting Rod and Main Bearings

2. Turn the start switch to the ON position.

3. Use the electronic service tool to verify that the

intake manifold pressure is 0 kPa (0 psi). Check the 5 V sensor supply for the intake manifold pressure. Refer to Troubleshooting, “5 Volt Engine Pressure Sensor Supply Circuit - Test”.

4. Use the electronic service tool to verify the throttle position status.

5. Run the engine until the speed is equal to the maximum no-load speed.

6. If the maximum no-load speed can not be obtained refer to Troubleshooting, “Throttle Switch Circuit - Test” and Troubleshooting, “Mode Selection Circuit - Test”.

7. If the engine speed is erratic refer to Troubleshooting, “Throttle Position Sensor Circuit

- Test”.

i01798136

Mechanical Noise (Knock) in Engine

Inspect the connecting rod and main bearings. Also, inspect the bearing surfaces (journals) on the crankshaft. Replace any damaged parts.

i01798137

Noise Coming from Cylinder

Probable Causes

Fuel quality

•

Fuel injection nozzles

•

Valve lash

•

Recommended Actions

Fuel Quality

Check the fuel quality. Remove unsatisfactory fuel from the fuel tank. Install new fuel filters. Use the proper grade of clean fuel in the fuel tank.

Fuel Injection Nozzles

Probable Causes

Accessory equipment

•

1. Remove the fuel injection nozzles from the cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

60 Troubleshooting Section

3. Ensure that the repairs have eliminated the problems.

Valve Lash

Refer to Troubleshooting, “Excessive Valve Lash”.

i01798138

Poor Acceleration or Response

Probable Causes

Refer to the logged codes.

•

Fuel supply

•

Individual malfunctioning cylinders

•

Valve lash

•

Low compression

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

ECM parameters

•

Intake manifold pressure (engines that are

•

turbocharged)

3. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

4. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Test”.

5. Check that the fuel lines are tight and secured properly.

6. Check for fuel supply lines that are restricted.

7. Check the fuel filters.

8. Visually check the fuel tank for fuel. The fuel

gauge may be faulty.

9. If the engine has a water separator, check for water in the fuel.

10. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

11. If the temperature is below 0 for solidified fuel (wax).



C (32



F), check

Individual Malfunctioning Cylinder

1. With the engine speed at a fast idle, loosen

the high pressure fuel line to the fuel injection nozzle of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the fuel line to the fuel injection nozzle.

Recommended Repairs

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.

Fuel Supply

NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Test”.

2. Ensure that the fuel system has been primed.

Refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”.

2. Individually repeat this procedure for each fuel injection nozzle.

3. If there is no reduction in the engine speed proceed to “Check the Fuel Injection Nozzles”.

4. If there is a reduction in engine speed proceed to “Valve Lash”.

Valve Lash

1. Check the valve lash and reset the valve lash, if

necessary. Refer to Systems Operation, Testing and Adjusting, “Engine Valve lash - Inspect and Adjust”.

2. If the repair does not eliminate the fault proceed to “Check for Low Compression”.

Check for Low Compression

1. Remove the fuel injection nozzles and perform a

compression test. Refer to Systems Operation, Testing and Adjusting, “Compression - Test ”data.

Troubleshooting Section

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the faults.

4. If the repair does not eliminate the fault proceed

to “Check the Fuel Injection Nozzles”.

Examples of low compression are shown in the following list:

Mechanical problem

•

Faulty piston rings

•

Worn cylinder bores

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

Check the Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the

cylinder head. Refer to Disassembly and Assembly, “Fuel Injection Nozzle - Remove”.

6. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The adjustment of the wastegate is set at the factory. If adjustment of the wastegate is required then the turbocharger must be replaced.

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

9. If the fault has not been eliminated proceed to

“ECM Parameters”.

ECM Parameters

1. Ensure that the problem is not a programmed

parameter.

2. Use the electronic service tool in order to ensure that the correct mode was selected.

3. Use the electronic service tool to verify the correct engine rating for the engine.

4. Use the electronic service tool to verify the maximum engine speed limit.

2. Check the fuel injection nozzles. Refer to Testing and Adjusting, “Fuel Injection Nozzle - Test”.

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated,proceed to “Check the Turbocharger (if equipped)”.

Check the Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100 Series are nonserviceable items. If any mechanical fault exists then the turbocharger must be replaced.

1. Ensure that the mounting bolts for the turbocharger are tight.

2. Check that the turbocharger drain is not blocked or restricted.

3. Check that the turbocharger housing is free of dirt and debris.

5. Use the electronic service tool to reset the parameters to the OEM specifications.

6. Ensure that the repairs have eliminated the performance problems.

7. If the repairs have not eliminated the faults proceed to “Check Intake Manifold Pressure”.

Check Intake Manifold Pressure (Engines that are turbocharged)

1. Turn the start switch to the ON position.

2. Use the electronic service tool to observe the

intake manifold pressure. The intake manifold pressure should be 0 kPa (0 psi).

5. Check that the turbine blades rotate freely on the turbocharger. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

62 Troubleshooting Section

Troubleshooting with a Diagnostic Code

i01798139

CID 0041 FMI 03 8v Sensor Power Supply, Voltage More Than Normal

Conditions Which Generate This Code:

The ECM has been powered for at least three

•

seconds.

The ECM reads signal voltage that is below

•

normal.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to idle or a safe speed. The engine will remain at idle or safe speed while the diagnostic codes remain active.

The ECM detects all of the following conditions:

The ECM has been powered for at least three

•

seconds.

The ECM reads signal voltage that is above

•

normal.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to low idle or a safe speed. The engine will remain at low idle or safe speed while the diagnostic code remains active.

Possible Performance Effect:

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

Possible Performance Effect:

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

i01798141

CID 0091 FMI 02 Throttle Demand Sensor Erratic Or Intermittent

Conditions Which Generate This Code:

If the engine is equipped with a throttle switch then the signal from this switch is invalid.

If the engine is equipped with a throttle position sensor then the signal from the throttle idle validation switch is invalid.

i01798140

CID 0041 FMI 04 8v Sensor Power Supply, Voltage Less Than Normal

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Possible Performance Effect:

The engine speed defaults to low idle or a predetermined safe speed.

The engine will remain at this speed while the diagnostic code remains active.

Troubleshooting Section

The reduction of speed is determined by the current speed of the engine.

When a fault is detected and the engine is above the predetermined safe speed, the engine will reduce speed to the safe speed.

When a fault is detected and the engine is below the predetermined safe speed, the engine will match the correct speed.

The throttle switch is ignored by the ECM until the fault is repaired.

The throttle switch will also be ignored by the ECM until the keyswitch has been turned to the OFF position and then back to the ON position.

Troubleshooting:

Proceed to “Test Step 1” if the engine is equipped with a throttle switch.

Proceed to “Test Step 2” if the engine is equipped with a throttle position sensor.

Test Step 1.

Perform the following diagnostic procedure: “Throttle Switch Circuit - Test”

System Response:

The ECM will log the diagnostic code. The diagnostic codes may be viewed on the electronic service tool.

The ECM will return the engine to low idle or to the predetermined safe speed while the diagnostic code remains active.

Possible Performance Effect:

Low power

•

Reduced engine speed

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Switch Circuit - Test”

Results:

OK – STOP.

•

i01798143

CID 0091 FMI 04 Throttle Demand Sensor Shorted Low

Results:

OK – STOP.

•

Test Step 2.

Perform the following diagnostic procedure: “Throttle Position Circuit - Test”

Results:

OK – STOP.

•

i01798142

CID 0091 FMI 03 Throttle Demand Sensor Open Circuit Or Shorted High

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

The ECM has been powered for at least 3

•

seconds.

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

The ECM has been powered for at least 3

•

seconds.

The ECM reads a signal voltage that is below

•

normal.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to the low idle or to the predetermined safe speed while the diagnostic code remains active.

Possible Performance Effect:

Low power

•

Reduced engine speed

•

Troubleshooting:

The ECM reads a signal voltage that is above

•

normal.

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

64 Troubleshooting Section

Results:

OK – STOP.

•

i01798144

CID 0091 FMI 08 Throttle Demand Sensor Abnormal Signal

Conditions Which Generate This Code:

The ECM is not receiving a correct throttle position signal.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM returns the engine to low idle or a safe speed when the problem is detected. The diagnostic code is logged only if the engine is running. The electronic service tool will indicate DIAG and a throttle position of 0 percent while the diagnostic code is active. This will happen regardless of the position of the throttle pedal assembly. The engine will remain at low idle or at the safe speed while the code is active.

i01798145

CID 0091 FMI 12 Throttle Demand Sensor Out Of Calibration

Conditions Which Generate This Code:

The ECM detects the following conditions:

A 5 volt failure

•

A 5 volt fault

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to the low idle or to the predetermined safe speed while the diagnostic code remains active.

Possible Performance Effect:

Low power

•

Reduced engine speed

•

Troubleshooting:

The diagnostic code is likely to be caused by one of the following conditions:

Open circuit for the throttle position sensor

•

Open circuit for the voltage supply

•

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

i01798146

CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit Or Shorted High

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

Signal voltage is above normal.

•

The ECM has been powered for at least 15

•

seconds.

Troubleshooting Section

CID 262-03 5V Sensor Power Supply, Voltage

•

More Than Normal and CID 262-04 5V Sensor Power Supply, Voltage Less Than Normal are not active.

System Response:

The ECM will set the engine oil pressure to a default value.

The electronic service tool will display “Open/Short High” for the engine oil pressure on the status screen.

The ECM will generate a CID 100 FMI 03 diagnostic code on the Data Link. The diagnostic code will be displayed on the diagnostic screen of the electronic service tool.

Troubleshooting:

Perform the following diagnostic procedure:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

Troubleshooting:

Perform the following diagnostic procedure:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

i01877641

CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Circuit

Conditions Which Generate This Code:

If the 5 volt connection to the sensor is an open circuit, this fault will result in a logged code.

The Electronic Control Module (ECM) detects all of the following conditions:

No other CID 0262 or CID 0102 codes are active.

•

i01798147

CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

The signal voltage that is below normal

•

The ECM has been powered for at least two

•

seconds.

CID 262-03 5V Sensor Power Supply, Voltage

•

More Than Normal and CID 262-04 5V Sensor Power Supply, Voltage Less Than Normal are not active.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM flags oil pressure as invalid data and a default value is used.

The engine speed is greater than 600 rpm.

•

Engine oil pressure signal is within the expected

•

range for this failure mode.

Engine oil pressure signal remains abnormally

•

constant because the variations in the sensor signal are too small.

All of the above conditions occur simultaneously

•

for a period of 10 seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will flag the engine oil pressure as invalid data. The engine oil pressure is set to a default value.

Possible Performance Effect:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

66 Troubleshooting Section

i01798148

CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit Or Shorted High

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The ECM reads a signal voltage that is above

•

normal.

The ECM has been powered for at least fifteen

•

seconds.

CID 262-03 5V Sensor Power Supply Voltage

•

More Than Normal and CID 262-04 5V Sensor Power Supply Voltage Less Than Normal are not active.

System Response:

i01798149

CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The ECM detects a signal voltage that is below

•

normal.

The ECM has been powered for at least fifteen

•

seconds.

CID 262-03 5V Sensor Power Supply, Voltage

•

More Than Normal and CID 262-04 5V Sensor Power Supply, Voltage Less Than Normal are not active.

System Response:

The ECM will set the intake manifold pressure to a default value.

The electronic service tool will display “Open/Short High” for the intake manifold pressure on the status screen.

The ECM will generate a CID 102 FMI 03 diagnostic code on the Data Link. The diagnostic code will be displayed on a diagnostic screen of the electronic service tool.

Possible Performance Effect:

The engine could have low power while the diagnostic code is active.

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

The ECM will set intake manifold pressure to a default value.

The electronic service tool will display “Short to Ground” for the intake manifold pressure on the status screen.

The ECM will generate a CID 102 FMI 04 diagnostic code on the Data Link. The diagnostic code will be displayed on a diagnostic screen of the electronic service tool.

Possible Performance Effect:

The engine could have low power while the diagnostic code is active.

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

Troubleshooting Section

i01877642

CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Open Circuit

Conditions Which Generate This Code:

If the 5 volt connection to the sensor is an open circuit, this fault will result in a logged code.

The Electronic Control Module (ECM) detects all of the following conditions:

No other CID 0262 or CID 0102 codes are active.

•

The engine speed is greater than 600 rpm.

•

The pressure sensor signal from the intake

•

manifold is within the expected range for this failure mode.

The pressure sensor signal from the intake

•

manifold remains abnormally constant because the variations in the sensor signal are too small.

All of the above conditions occur simultaneously

•

for a period of 30 seconds.

System Response:

The ECM has been powered for at least fifteen

•

seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM flags the intake air temperature as invalid data and a default value is used.

Possible Performance Effect:

Low power

•

Poor cold starting

•

Troubleshooting:

Perform the following diagnostic procedure: “Engine Temperature Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

i01798151

CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will flag the intake manifold pressure as invalid data. The intake manifold pressure is set to a default value.

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

i01798150

CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit Or Shorted High

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The ECM reads signal voltage that is below

•

normal.

The ECM has been powered for at least fifteen

•

seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM flags the intake air temperature as invalid data and a default value is used.

Possible Performance Effect:

Low power

•

Poor cold starting

•

The ECM reads signal voltage that is above

•

normal.

68 Troubleshooting Section

Troubleshooting:

Perform the following diagnostic procedure: “Engine Temperature Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

i01798152

CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit Or Shorted High

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The ECM reads signal voltage that is above

•

normal.

The ECM has been powered for at least three

•

seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM flags coolant temperature as invalid data and a default value is used.

Possible Performance Effect:

i01798153

CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The ECM reads signal voltage that is below

•

normal.

The ECM has been powered for at least three

•

seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM flags coolant temperature as invalid data and a default value is used.

Possible Performance Effect:

Engine misfires

•

Low power

•

Reduced engine speed (rpm)

•

Poor cold starting

•

Troubleshooting:

Engine misfires

•

Low power

•

Reduced engine speed (rpm)

•

Poor cold starting

•

Troubleshooting:

Further troubleshooting is required.

Perform the following diagnostic procedure: “Engine Temperature Sensor Open/Short Circuit - Test”

Results:

OK – STOP.

•

Further troubleshooting is required.

Perform the following diagnostic procedure: “Engine Temperature Sensor Open/Short Circuit - Test”

Results:

OK – STOP.

•

Troubleshooting Section

i01798154

CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent

Conditions Which Generate This Code:

Note: If both of the following diagnostic codes are active, then the fuel injection pump has suffered a complete failure of the electrical supply:

174-02

•

342-02

•

Both of the diagnostic codes will be active if there has been a communication fault between the Electronic Control Module (ECM) and the CAN Data Link for the fuel injection pump. When only one of the diagnostic codes is active there is not a fault with the electrical supply for the fuel injection pump.

If the ECM has detected 174-02 only, then one of the following conditions has been detected:

i01798155

CID 0247 FMI 09 J1939 Datalink, Abnormal Update

Conditions Which Generate This Code:

The ECM has detected a loss of communications with another device on the J1939 data link.

System Response:

Some system functions may not operate properly.

The ECM will generate a CID 247 FMI 09 diagnostic code on the Data Link. The diagnostic code will be displayed on a diagnostic screen of the electronic service tool.

Perform the following diagnostic procedure: “Troubleshooting, “CAN Data Link Circuit - Test”.”

Results:

– STOP.

•

The fuel temperature signal is erratic.

•

Fuel temperature that is intermittent.

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM logs the diagnostic code only if the engine is running.

Possible Performance Effect:

The engine may shut down.

•

The engine will have low power.

•

Troubleshooting:

Further troubleshooting is required.

Perform the following diagnostic procedure: “Fuel Injection Pump Circuit - Test”

Results:

OK – STOP.

•

i01798156

CID 0253 FMI 02 Incorrect ECM Software

Conditions Which Generate This Code:

The personality module is the software that is loaded into the ECM in order to determine the power and torque outputs for a particular engine model and/or a particular engine application. The engine’s personality module is loaded by the factory. A replacement personality module can be loaded into the ECM. The diagnostic code 0253 indicates that the personality module is neither the original personality module nor a replacement of the original personality module.

Note: The personality module is a flash personality module. The personality module is installed into the ECM by flash programming.

System Response:

The ECM will not log any diagnostic code except diagnostic code 0253. The diagnostic code may be viewed on a display module or on the electronic service tool. As a result of this code, the fuel injection pump is disabled for the engine. The engine will not start, and the electronic service tool will not be able to reset the diagnostic code in order to allow the engine to start.

70 Troubleshooting Section

Possible Performance Effect:

Engine shutdown

•

Troubleshooting:

Check the part number of ECM Personality Module. Ensure that the personality module part number agrees with the original engine arrangement.

Expected Result:

The correct personality module is installed in the ECM.

Results:

OK – The correct personality module is installed

•

in the ECM. STOP.

Not OK – The correct personality module is not

•

installed in the ECM.

Repair: Reprogram the ECM with the correct personality module. Refer to Troubleshooting, “Flash Programming”.

STOP.

i01798157

Troubleshooting:

Further troubleshooting is required.

Perform the following diagnostic procedure: “5 Volt Pressure Sensor Supply Circuit - Test”

Results:

OK – STOP.

•

i01798158

CID 0262 FMI 04 5v Sensor Power Supply, Voltage Less Than Normal

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The ECM reads signal voltage that is below

•

normal.

The ECM has been powered for at least three

•

seconds.

CID 0262 FMI 03 5v Sensor Power Supply, Voltage More Than Normal

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The ECM reads signal voltage that is above

•

normal.

The ECM has been powered for at least three

•

seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Possible Performance Effect:

Low power

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Possible Performance Effect:

Low power

•

Possible engine misfire

•

Troubleshooting:

Further troubleshooting is required.

Perform the following diagnostic procedure: “5 Volt Pressure Sensor Circuit - Test”

Results:

OK – STOP.

•

Possible engine misfire

•

Troubleshooting Section

i01897931

CID 0266 FMI 02 Incorrect Crank-without-inject inputs

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

The Crank Without Injection input from the

•

normally closed relay is above 11.5 VDC.

The Crank Without Injection input from the

•

normally open relay is below 0.5 VDC.

System Response:

The diagnostic code may be viewed on a display module or on the electronic service tool.

The Crank Without Injection will be disabled.

Possible Performance Effect:

There may be a slight change in engine response.

The ECM will limit the maximum engine speed to 1200 rpm.

If the signal is lost from both of the engine speed/timing sensors, the ECM will shut down the engine.

Perform the following diagnostic procedure: “Engine Speed/Timing Sensor Circuit - Test”

Results:

OK – STOP.

•

REPAIRED, OK – STOP.

•

i01798160

CID 0320 FMI 11 Speed And Timing Sensor Loss Of Signal

None

•

Troubleshooting:

Perform the following diagnostic procedure: “Crank Without Injection Circuit - Test”

Results:

OK – STOP.

•

i01798159

CID 0320 FMI 02 Speed And Timing Sensor Intermittent Loss Of Signal

Conditions Which Generate This Code:

The signal for the speed/timing sensor is intermittent. This speed/timing sensor is located near the flywheel housing.

System Response:

Conditions Which Generate This Code:

The signal for the speed/timing sensor is lost. This speed/timing sensor is located near the flywheel housing.

System Response:

The Electronic Control Module (ECM) will use the speed/timing sensor in the fuel injection pump to determine engine speed. The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Possible Performance Effect:

There may be a slight change in engine response.

The ECM will limit the maximum engine speed to 1200 rpm.

If the signal is lost from both of the engine speed/timing sensors, the ECM will shut down the engine.

Perform the following diagnostic procedure: “ Engine Speed/Timing Sensor Circuit - Test”

Results:

OK – STOP.

•

REPAIRED, OK – STOP.

•

72 Troubleshooting Section

i01798161

CID 0342 FMI 02 Speed And Timing Sensor No.2 Intermittent Signal

Conditions Which Generate This Code:

Note: If both of the following diagnostic codes are active, then the fuel injection pump has suffered a complete failure of the electrical supply:

0174-02

•

0342-02

•

Both of the diagnostic codes will be active if there has been a communication fault between the Electronic Control Module (ECM) and the CAN data link for the fuel injection pump. If only the 0342-02 is active there is not a fault with the electrical supply for the fuel injection pump.

The signal for the speed/timing sensor in the fuel injection pump is intermittent or lost for less than one second.

i01798162

CID 0774 FMI 02 Throttle Demand Sensor No.2 Erratic Or Intermittent

Conditions Which Generate This Code:

The ECM detects one of the following conditions:

Erratic data

•

Intermittent data

•

Incorrect data

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to low idle or to a safe speed while the diagnostic code is active.

Possible Performance Effect:

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The ECM will force the engine to a default value or a safe speed. The diagnostic code may be viewed on the electronic service tool.

Possible Performance Effect:

The engine will shut down.

Test Step 1.

Perform the following diagnostic procedure: “Fuel Injection Pump Circuit - Test”

Results:

OK – STOP.

•

Test Step 2.

Perform the following diagnostic procedure: “CAN Data Link Circuit - Test”

Results:

OK – STOP.

•

REPAIRED, OK – STOP.

•

The engine speed defaults to low idle or a predetermined safe speed.

The engine will remain at this speed while the diagnostic code remains active.

The reduction of speed is determined by the current speed of the engine.

When a fault is detected and the engine is above the predetermined safe speed, the engine will reduce speed to the safe speed.

When a fault is detected and the engine is below the predetermined safe speed, the engine will match the correct speed.

The throttle is ignored by the ECM until the fault is repaired.

The throttle switch will also be ignored by the ECM until the keyswitch has been turned to the OFF position and then back to the ON position.

Low power

•

Reduced engine speed

•

Perform the following diagnostic procedure: “Throttle Switch Circuit - Test”

Troubleshooting Section

Results:

OK – STOP.

•

i01798163

CID 0774 FMI 03 Throttle Demand Sensor No.2 Open Circuit Or Shorted High

Conditions Which Generate This Code:

The ECM detects one of the following conditions:

Voltage for the throttle position sensor is above

•

normal.

Invalid throttle position signal

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Invalid throttle position signal

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to low idle or to a safe speed while the diagnostic code is active.

Possible Performance Effect:

Low power

•

Reduced engine speed

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

i01798165

The ECM will return the engine to low idle or to a safe speed while the diagnostic code is active.

Possible Performance Effect:

Low power

•

Reduced engine speed

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

i01798164

CID 0774 FMI 04 Throttle Demand Sensor No.2 Shorted Low

Conditions Which Generate This Code:

The ECM detects one of the following conditions:

Voltage for the throttle position sensor is below

•

normal.

CID 0774 FMI 08 Throttle Demand Sensor No.2 Abnormal Signal

Conditions Which Generate This Code:

The ECM detects one of the following conditions:

Voltage for the throttle position sensor is abnormal.

•

Invalid throttle position signal

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to low idle or to a safe speed while the diagnostic code is active.

Possible Performance Effect:

Low power

•

Reduced engine speed

•

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

74 Troubleshooting Section

Results:

OK – STOP.

•

i01798166

CID 0774 FMI 12 Throttle Demand Sensor No.2 Out Of Calibration

Conditions Which Generate This Code:

The ECM detects one of the following conditions:

Throttle position sensor signal is abnormal.

•

Failure of the throttle position sensor

•

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will return the engine to low idle or to a safe speed while the diagnostic code is active.

Possible Performance Effect:

Low power

•

Reduced engine speed

•

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Possible Performance Effect:

Perform the following diagnostic procedure: “Fuel Injection Pump Circuit - Test”

Results:

OK – STOP.

•

i01798167

CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than Normal

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

There are two conditions that will generate this code:

The fuel temperature may be above the recommended maximum operating temperature. The Perkins recommended maximum operating fuel temperature is 70 fuel injection pump. The electronic fuel injection pump will note that the fuel temperature is too high.

There may be an internal fault within the fuel injection pump.



C (158.0



F) at the inlet to the

OK – STOP.

•

i01877645

CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off

Conditions Which Generate This Code:

The ECM still receives signals from the relay of the fuel injection pump even though the ECM has already switched off the relay.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The fuel injection pump will reduce the available quantity of fuel for injection if the fuel temperature is too high and the diagnostic code is still active. E054 High Fuel Temperature Derate is the event code that will be logged on the ECM.

Possible Performance Effect:

The fuel injection pump will be derated.

•

Low engine power

•

Reduced engine speed

•

Troubleshooting Section

Test Step 1.

Check the fuel system for restrictions.

Check the fuel temperature.

Check for active diagnostic codes

Results:

OK – STOP.

•

Test Step 2.

If the fault has not been eliminated refer to Systems Operation, Testing and Adjusting, “Fuel System Inspect”.

Results:

OK – STOP.

•

i01798168

CID 1684 FMI 02 Fuel Injection Pump, Software Failure

Troubleshooting:

Contact the Perkins Technical Support Centre in order to check if the software version is correct. Also check that there have been no software updates.

If the problem still exists contact the Perkins Technical Support Centre in order to change the fuel injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultation.

Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

Check for active diagnostic codes.

Results:

OK – STOP.

•

i01798169

CID 1684 FMI 03 Fuel Injection Pump, Fuelling Fault

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The fuel injection pump will detect the following condition:

An internal failure of the fuel injection pump

•

software.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will not allow the engine to start while the diagnostic code is active.

If the engine is running and the diagnostic code becomes active, the ECM will cause the engine to shutdown.

Possible Performance Effect:

The ECM will cause the engine to shutdown.

The engine will not start while the diagnostic code is active.

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The fuel injection pump will detect the following condition:

An internal problem with the fuel injection pump

•

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

System Response:

The ECM will have no response to this active code. The engine may have reduced power.

Possible Performance Effect:

An incorrect amount of fuel may be injected into the cylinders. Continuing to use the engine under these conditions may lead to engine failure.

Troubleshooting:

Contact the Perkins Technical Support Centre in order to check if the software version is correct. Also check that there have been no software updates.

76 Troubleshooting Section

Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

Check for active diagnostic codes.

Results:

OK – STOP.

•

i01798170

CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The fuel injection pump detects one of the following conditions while the engine is running:

Supply voltage below normal

•

i01798171

CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects the following improper response from the fuel injection pump.

Invalid “PWM” signal from the fuel injection pump

•

This invalid “PWM” is likely to be caused by a fault in the CAN Data Link in either the ECM or in the fuel injection pump.

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will cause the fuel injection pump to stop injecting fuel. The ECM will then cause the engine to shut down while the diagnostic code is active.

Troubleshooting:

A. Connect a test ECM in order to determine if

the problem is in the original ECM or in the fuel injection pump.

Intermittent signal

•

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

System Response:

Possible Performance Effect:

The diagnostic code is logged, but there will be no other system response.

There is no obvious effect on engine performance.

•

Troubleshooting:

Further troubleshooting is required.

Perform the following diagnostic procedure: “Fuel Injection Pump Circuit - Test”

Results:

OK – STOP.

•

Note: The parameters of the test ECM must match the parameters in the suspect ECM. If the test ECM resolves the problem, reconnect the suspect ECM. Verify that the problem returns. If the problem returns, replace the suspect ECM.

B. If the ECM is OK, contact the Perkins Technical

Support Centre in order to change the fuel injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultation.

Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

C. Check for active diagnostic codes.

Results:

OK – STOP.

•

Troubleshooting Section

i01798172

CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

System Response:

The ECM will cause the fuel injection pump to stop injecting fuel. The ECM will then cause the engine to shut down while the diagnostic code is active.

Possible Performance Effect:

The engine will shut down.

Troubleshooting:

Refer to Troubleshooting, “Fuel Injection Pump Circuit - Test”.

System Response:

The fuel injection pump will use the engine speed/timing sensor in order to set the engine timing. The ECM will derate the engine power by 20% while the diagnostic code is active.

Possible Performance Effect:

The engine will experience any of the following conditions:

Small loss of engine performance

•

Increased emissions

•

The engine may be difficult to start.

•

Troubleshooting:

Further troubleshooting is required.

Test Step 1.

Check for the following active code:

Diagnostic code 320-02

•

Diagnostic code 320-11

•

Check for active diagnostic codes.

Results:

OK – STOP.

•

i01798173

CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The fuel injection pump detects one of the following conditions:

The fuel injection pump did not receive a position

•

signal.

The signal that is received by the fuel injection

•

pump is incorrect.

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Results:

Codes Active – Proceed to Test Step 2.

•

Test Step 2.

Perform the following diagnostic procedure: “Engine Speed/Timing Sensor Circuit - Test”

Results:

OK – STOP.

•

Not OK – Proceed to Test Step 3.

•

Test Step 3.

Pay close attention to the following areas:

P1/J1 ECM connector

•

P40/J40 Fuel injection pump connector

•

P1:59 Engine position

•

P40:8 Engine position

•

Refer to Troubleshooting, “Electrical Connectors

- Inspect”.

78 Troubleshooting Section

Results:

OK – Proceed to Test Step 4.

•

Test Step 4.

Check continuity between the following connections:

P1:59 Engine position

•

P40:8 Engine position

•

Expected Result:

If the fault is cleared then STOP.

If the fault still exists, repair the wire harness or replace the wire harness.

Ensure that the repairs have eliminated the problem.

Check for active diagnostic codes.

Results:

OK – STOP.

•

i01798174

CID 1684 FMI 09 Fuel Injection Pump, CAN Fault

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The fuel injection pump detects one of the following conditions:

The engine will shut down.

•

The engine will not start.

•

Troubleshooting:

Further troubleshooting is required.

Connect a test ECM in order to determine if the original ECM is the cause of the problem.

Expected Result:

If the fault is cleared then STOP.

If the fault is still active, perform the following Troubleshooting, “CAN Data Link Circuit - Test”.

If the fault is cleared then STOP.

If the fault is still active, contact the Perkins Technical Support Centre in order to change the fuel injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultation.

Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

Check for active diagnostic codes.

Results:

OK – STOP.

•

Failure of the CAN Data Link

•

The ECM sends incorrect data.

•

The fuel injection pump sends incorrect data.

•

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

System Response:

The ECM will cause the fuel injection pump to stop the injection of fuel.

Possible Performance Effect:

The ECM will cause the following conditions:

i01798175

CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects one of the following improper responses from the fuel injection pump.

Open circuit

•

Wire shorted high.

•

Troubleshooting Section

Wire shorted low.

•

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

System Response:

The engine may shut down while the diagnostic code is active. Also, the engine may not start while the diagnostic code is active.

Troubleshooting:

Further troubleshooting is required.

Test Step 1.

Use a multimeter to check the following connections:

J1:1

•

P40:5

•

Note: While the engine is cranking and running, the battery voltage at terminal P40:5 should drop to 0 volts.

Ensure that the problem has been eliminated.

Results:

Check for active diagnostic codes – STOP.

•

Test Step 2.

Connect a test ECM to the engine in order to determine if the original ECM is causing the problem.

Check for active diagnostic codes.

Results:

OK – STOP.

•

i01798176

CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The problem is internal to the fuel injection pump.

There may be air in the fuel injection pump.

The voltage and/or resistance at the connectors for the fuel injection pump are incorrect.

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

System Response:

The ECM will derate the engine power by 20% while the diagnostic code is active.

Possible Performance Effect:

The engine may experience any of the following conditions while the diagnostic code remains active:

Low power

•

Reduced engine speed

•

Troubleshooting:

Further troubleshooting is required.

Results:

OK – STOP.

•

Not OK – Proceed to Test Step 3.

•

Test Step 3.

Contact the Perkins Technical Support Centre in order to change the fuel injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultation.

Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

Test Step 1.

Check the tightness of all fuel line connections. Check for air in the fuel injection pump. Refer to Operation and Maintenance Manual, “Fuel System

- Prime”.

Results:

OK – Proceed to Test Step 2.

•

Test Step 2.

Refer to Troubleshooting, “Fuel Injection Pump Circuit - Test”.

80 Troubleshooting Section

Check for active diagnostic codes.

Results:

OK – STOP.

•

i01798177

CID 1684 FMI 12 Fuel Injection Pump, Device Failure

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

The problem is internal to the fuel injection pump.

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

System Response:

The ECM will derate the engine power by 20% while the diagnostic code is active.

Possible Performance Effect:

i01798178

CID 1684 FMI 14 Fuel Injection Pump, No Communications

Conditions Which Generate This Code:

The ECM detects a communication failure with the fuel injection pump.

Also, the connectors for the fuel injection pump to the wiring harness may be disconnected or faulty.

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Troubleshooting:

Further troubleshooting is required.

Test Step 1.

Perform a Troubleshooting, “Fuel Injection Pump Circuit - Test”.

While the diagnostic code is active the engine will experience the following conditions:

Low power

•

Reduced engine speed

•

Troubleshooting:

Contact the Perkins Technical Support Centre in order to check if the software version is correct. Also check that there have been no software updates.

Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

Check for active diagnostic codes.

Results:

OK – STOP.

•

Results:

OK – Proceed to Test Step 2.

•

Test Step 2.

Connect a test ECM in order to determine if the problem is in the original ECM or in the fuel injection pump.

Check for active diagnostic codes.

Results:

OK – Proceed to Test Step 3.

•

Test Step 3.

Contact the Perkins Technical support Centre in order to check if the software version is correct. Also check that there have been no software updates.

Troubleshooting Section

Check for active diagnostic codes.

Results:

OK – STOP.

•

i01798179

CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invalid State

Conditions Which Generate This Code:

The ECM has detected one of the following conditions:

Erratic data

•

Intermittent data

•

i01798180

CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invalid State

Conditions Which Generate This Code:

The ECM detects one of the following conditions:

Erratic data

•

Intermittent data

•

Incorrect data

•

System Response:

The engine speed fails to disengage from the set speed.

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will have no response to this active code. There is no loss of engine performance.

Incorrect data

•

System Response:

The ECM will return the engine to the last good mode selection or setting. The ECM will not allow the engine to advance to another mode selection until the problem is repaired.

Possible Performance Effect:

The engine will start but the engine will have reduced engine speed.

Troubleshooting:

Refer to Troubleshooting, “Mode Selection Circuit Test”.

Results:

OK – STOP.

•

Troubleshooting:

Further troubleshooting is required.

Refer to Troubleshooting, “Throttle Switch Circuit Test”.

Results:

OK – STOP.

•

i01798181

CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid State

Conditions Which Generate This Code:

The ECM detects one of the following conditions:

Erratic data

•

Intermittent data

•

Incorrect data

•

82 Troubleshooting Section

System Response:

The engine speed fails to disengage from the set speed.

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

The ECM will have no response to this active code. There is no loss of engine performance.

Troubleshooting:

Further troubleshooting is required.

Refer to Troubleshooting, “Throttle Switch Circuit Test”.

Results:

OK – STOP.

•

Troubleshooting Section

Troubleshooting with an Event Code

i01798182

Event Codes

Note: If a diagnostic code has already been logged then any associated event code to that fault will not be logged as well.

The ECM can log events. Events refer to engine operating conditions such as low oil pressure or high coolant temperature. Logged events usually indicate a mechanical problem instead of an electronic system problem.

Programmable Engine Parameters

The following features may be programmed:

Engine Warning

•

Results:

OK – STOP.

•

i01897925

E016 High Engine Coolant Temperature Shutdown

Conditions Which Generate This Code:

The engine has been running for at least 3 minutes. The engine coolant temperature has exceeded the trip point and the delay time has expired.

System Response:

If the engine shutdown is “ENABLED” the fuel will be shut off. The event will be logged.

Possible Performance Effect:

The engine is shut down.

Engine Derate

•

Engine Shutdown

•

When the features are activated the event will be logged in the ECM.

i01798183

E015 High Engine Coolant Temperature Derate

Conditions Which Generate This Code:

The engine has been running for at least 3 minutes. The engine coolant temperature has exceeded the trip point and the delay time has expired.

System Response:

The alarm output is activated. The event is logged.

Possible Performance Effect:

Troubleshooting:

Refer to Troubleshooting, “Coolant Temperature Is Too High”.

Results:

OK – STOP.

•

i01798184

E017 High Engine Coolant Temperature Warning

Conditions Which Generate This Code:

The engine has been running for at least 3 minutes. The engine coolant temperature has exceeded the trip point and the delay time has expired.

System Response:

The alarm output is activated. The event is logged.

The engine power is reduced.

Troubleshooting:

Refer to Troubleshooting, “Coolant Temperature Is Too High”.

Possible Performance Effect:

The engine operation is not immediately affected. However, if the coolant temperature continues to rise, the engine will be derated.

84 Troubleshooting Section

Troubleshooting:

Refer to Troubleshooting, “Coolant Temperature Is Too High”.

Results:

OK – STOP.

•

i01798185

E025 High Intake Air Temperature Derate

Conditions Which Generate This Code:

The engine has been running for at least 3 minutes. The intake air temperature has exceeded the setpoint and the delay time has expired. No other codes for the intake manifold air temperature are active.

System Response:

The alarm output is activated. The event is logged.

Possible Performance Effect:

The engine power is reduced.

Troubleshooting:

Refer to Troubleshooting, “Intake Manifold Air Temperature Is Too High”.

The ECM detects the following conditions:

The intake manifold air temperature is greater

•

than 76

The intake manifold air temperature is greater

•

than 135



C (168



C (275



F) for the 1106 engine.



F) for the 1104 turbocharged

engine.

The intake manifold air temperature is greater

•

than 82



C (179



F) for the aftercooled 1104

turbocharged engine.

The intake manifold air temperature is greater

•

than 112



C (233



F) for the 1104 naturally

aspirated engine.

The ECM will reset when the following conditions are met:

The intake manifold air temperature is less than

•



C (165

The intake manifold air temperature is less than

•



133

The intake manifold air temperature is less

•

than 80

C (271



C (176



F) for the 1106 engine.



F) for the 1104 turbocharged engine.



F) for the aftercooled 1104

turbocharged engine.

The intake manifold air temperature is less than

•

110



C (230



F) for the 1104 naturally aspirated

engine.

System Response:

The alarm output is activated. The code is logged.

Results:

OK – STOP.

•

i01798186

E027 High Intake Air Temperature Warning

Conditions Which Generate This Code:

The engine has been running for at least 3 minutes. The intake manifold air temperature has exceeded the trip point for the machine’s application and the delay time of 4 seconds has expired. No other codes for the intake manifold air temperature are active. The ECM will reset when the intake manifold air temperature cools below the trip point for the machine application.

Possible Performance Effect:

The ECM will derate the engine. The ECM will continue to derate the engine at a higher rate as the intake manifold air temperature rises.

Troubleshooting:

Refer to Troubleshooting, “Intake Manifold Air Temperature Is Too High”.

Results:

OK – STOP.

•

Troubleshooting Section

i01798187

E040 Low Engine Oil Pressure Shutdown

Conditions Which Generate This Code:

The engine has been running for at least 5 seconds and the engine speed is above 500 RPM. The engine oil pressure is less than the trip point and the delay time has expired. No codes for the engine oil pressure sensor are active.

Ta bl e 1 2

1104

Engine

Speed

Tr i p

Point

Reset

Point

Ta bl e 1 3

Engine

Speed

Tr ip

Point

Reset

Point

700 1200 1800 2400

50 kPa

(7 psi)

71 kPa

(10.2 psi)

700 1200 1800 2500

150 kPa

(21.7

psi)

171 kPa

(24.8

psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

1106

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

i01798188

E054 High Fuel Temperature Derate

Conditions Which Generate This Code:

The engine has been running for at least 3 seconds and the fuel temperature is above the trip point for the machine’s application.

System Response:

The warning lamp will flash while the “Derate” is active.

The electronic service tool will display “Engine Derate” in the first engine status box on any electronic service tool status screen.

The ECM will generate a EID E054 event code on the Data Link. The event code will be displayed on a diagnostic screen of the electronic service tool.

Troubleshooting:

There may be a problem with the fuel system.

•

There may be a problem with the fuel temperature

•

sensor.

Test Step 1. Check for Diagnostic Codes.

A. Connect the electronic service tool to the service

tool connector.

System Response:

If the engine shutdown input is “ENABLED” the fuel will be shut off. The code is logged.

Possible Performance Effect:

The engine is shut down.

Troubleshooting:

Refer to Troubleshooting, “Low Engine Oil Pressure”.

Results:

OK – STOP.

•

B. Turn the keyswitch to the ON position. The

engine should be off.

C. Check for any active diagnostic codes or logged

diagnostic codes.

Expected Result:

There should be no diagnostic codes that are present.

Results:

OK – Proceed to Test Step 2.

•

Not OK

•

Repair: Repair the diagnostic codes that are present. Refer to the appropriate topic in the “Troubleshooting With a Diagnostic Code” section of this manual.

Ensure that the repair eliminates the problem.

STOP.

86 Troubleshooting Section

Test Step 2. Perform a Check of the Fuel System.

A. Perform a check of the fuel system. Refer to the

appropriate topic in Testing and Adjusting for possible causes.

Expected Result:

There are no problems with the fuel system.

Results:

OK – There may be an intermittent problem.

•

Repair: Monitor the operation of the engine.

Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

Not OK

•

Repair: Repair the problem.

Troubleshooting:

There may be a problem with the fuel system.

•

There may be a problem with the fuel temperature

•

sensor.

Test Step 1. Check for Diagnostic Codes.

A. Connect the electronic service tool to the service

tool connector.

B. Turn the keyswitch to the ON position. The

engine should be off.

C. Check for any active diagnostic codes or logged

diagnostic codes.

Expected Result:

There should be no diagnostic codes that are present.

Results:

OK – Proceed to Test Step 2.

•

Ensure that the repair eliminates the problem.

STOP.

i01798189

E056 High Fuel Temperature Warning

Conditions Which Generate This Code:

The fuel temperature has exceeded the trip point and the delay time has expired. The ECM will reset the warning when the fuel temperature is above the reset value.

The ECM detects all of the following conditions:

The engine has been running at least three

•

minutes. This three minute delay begins once the engine speed is within 50 rpm of the low idle setting.

174-02 Fuel Temperature Sensor erratic or

•

intermittent

System Response:

The ECM will log the event. The event code can be viewed on the diagnostic screen of the electronic service tool.

Not OK

•

Repair: Repair the diagnostic codes that are present. Refer to the appropriate topic in the “Troubleshooting With a Diagnostic Code” section of this manual.

Ensure that the repair eliminates the problem.

STOP.

Test Step 2. Perform a Check of the Fuel System.

A. Perform a check of the fuel system. Refer to the

appropriate topic in Testing and Adjusting for possible causes.

Expected Result:

There are no problems with the fuel system.

Results:

OK – There may be an intermittent problem.

•

Repair: Monitor the operation of the engine.

Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

Troubleshooting Section

Not OK

•

Repair: Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

i01798190

E100 Low Engine Oil Pressure Warning

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of the following conditions:

Ta bl e 1 4

1104

Engine

Speed

Tr ip

Point

Reset

Point

Ta bl e 1 5

Engine

Speed

Tr i p

Point

Reset

Point

The engine has been running for at least 5

•

seconds. The engine speed is at least 500 rpm.

Engine oil pressure is low for 2 seconds.

•

100-03 “Engine Oil Pressure open circuit or

•

shorted high” is not active.

100-04 “Engine Oil Pressure shorted low” is not

•

active.

System Response:

The ECM will log the event.

Possible Performance Effect:

None

•

700 1200 1800 2400

50 kPa

(7 psi)

71 kPa

(10.2 psi)

700 1200 1800 2500

150 kPa

(21.7 psi)

171 kPa

(24.8 psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

1106

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

200 kPa

(29.0

psi)

221 kPa

(32.0

psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

200 kPa

(29.0 psi)

221 kPa

(32.0 psi)

Troubleshooting:

There may be a problem with the engine

•

lubrication system.

There may be a problem with the engine oil

•

pressure sensor.

Test Step 1. Check for Active Diagnostic Codes.

A. Connect the electronic service tool.

B. Turn the main power to the ON position.

C. Check for any Active Diagnostic Codes or

Logged Diagnostic Codes.

Expected Result:

There should be no diagnostic codes that are present.

Results:

OK – There are no diagnostic codes that are

•

present. Proceed to test step 2.

Not OK – There are diagnostic codes that are

•

present.

Repair: Repair the faults that caused the diagnostic codes that are present. Refer to the appropriate topic in the “Troubleshooting With a Diagnostic Code” section of this manual. Ensure that the repair eliminates the problem.

STOP.

Test Step 2. Perform a Check of the Engine Lubrication System.

A. Perform a check of the engine lubrication

system. Refer to the diagnostic procedure Troubleshooting, “Low Engine Oil Pressure”.

Expected Result:

There should be no problems with engine oil pressure.

Results:

OK – There are no problems with engine oil

•

pressure. There may be an intermittent problem.

Repair: Monitor the operation of the engine. Repair the problem. Ensure that the repair eliminates the problem.

STOP.

88 Troubleshooting Section

Not OK – There are problems with engine oil

•

pressure.

Repair: Repair the problem. Ensure that the repair eliminates the problem.

STOP.

i01798191

E190 Engine Overspeed Warning

Conditions Which Generate This Code:

Engine speed is above 3000 rpm for the 1104 for more than 0.6 seconds or the engine speed is above 3300 RPM for the 1106 for more than 0.6 seconds. The reset point for both the 1104 and 1106 is 2800 RPM.

Note: This Event Code represents an event. This does not represent an electronic system fault.

i01798192

E442 Engine Failed to Stop with a No-Fuel Command

Conditions Which Generate This Code:

The engine shutdown was slow when the keyswitch was turned to the OFF position.

The engine failed to shutdown when the keyswitch was turned to the OFF position.

The engine failed to shutdown when the fuel injection pump stopped fuel injection.

System Response:

If the engine still fails to shut down, the ECM will disable the power relay for the fuel injection pump.

The event code is logged in the ECM memory.

Possible Performance Effect:

System Response:

The event is logged in memory. The event may be viewed on a display module or the electronic service tool.

Possible Performance Effect:

None

Troubleshooting:

This event indicates excessive engine speed. This does not represent a problem with the Engine Control Module (ECM). This does not represent a problem with the Electronic Speed/Timing Sensor.

Engine Overspeed Warning

This event records the engine overspeed warning. No troubleshooting is required.

Expected Result:

Results:

OK – STOP.

•

Slow engine shutdown

Troubleshooting:

No troubleshooting will be required unless the diagnostic code 1684-09 is active.

Test Step 1.

Connect a test ECM in order to determine if the original ECM is the cause of the problem.

Note: The parameters of the test ECM must match the parameters in the suspect ECM.

If the test ECM resolves the problem, reconnect the suspect ECM.

Verify that the problem returns. If the problem returns, replace the suspect ECM.

Results:

OK – STOP.

•

Not OK – Proceed to Test Step 2.

•

Test Step 2.

Perform the following diagnostic procedure: “CAN Data Link Circuit - Test”

Troubleshooting Section

Results:

OK – STOP.

•

i01798193

E883 Engine Failed To Stop When Fuel Solenoid Disengaged

Conditions Which Generate This Code:

The engine shutdown was slow when the keyswitch was turned to the OFF position.

The engine failed to stop when the ECM disabled the fuel injection pump.

The engine failed to shutdown when the keyswitch was turned to the OFF position.

System Response:

The ECM attempts to shut down the engine by instructing the fuel injection pump to stop fuel injection.

Note: The parameters of the test ECM must match the parameters in the suspect ECM.

If the test ECM resolves the problem, reconnect the suspect ECM.

Verify that the problem returns with the suspect ECM.

If the problem returns, replace the suspect ECM.

Results:

OK – STOP.

•

Not OK – Proceed to Test Step 3.

•

Test Step 3.

Replace the fuel injection pump. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

Results:

OK – STOP.

•

The event code is logged in the ECM memory.

Possible Performance Effect:

Slow engine shutdown

Troubleshooting:

No troubleshooting will be required unless the diagnostic code 1684-10 is active.

Test Step 1.

Use a multimeter to check the following connections:

J1:1

•

P40:5

•

Ensure that the problem has been eliminated.

Results:

Check for active diagnostic codes – STOP.

•

Test Step 2.

Connect a test ECM to the engine in order to determine if the original ECM is causing the problem.

90 Troubleshooting Section

Diagnostic Functional Tests

i01798194

5 Volt Engine Pressure Sensor Supply Circuit - Test

System Operation Description:

Use this procedure under the following situation:

Use this procedure if another procedure has directed you here. Also use this procedure if any of the following diagnostic codes are active:

262-03 5 Volt Sensor Power Supply voltage more

•

than normal

262-04 5 Volt Sensor Power Supply voltage less

•

than normal

The following background information is related to this procedure:

The Electronic Control Module (ECM) supplies regulated +5 VDC to the following sensors:

J201/P201 Engine Oil Pressure Sensor

•

J200/P200 Intake Manifold Pressure Sensor

•

J40/P40 Throttle Sensor

•

The supply for the +5 V engine pressure sensor is routed from the ECM through ECM engine harness connector J1/P1 terminal 2 to terminal “A” of each pressure sensor connector. The supply voltage is

5.0 ± 0.5 VDC.

The +5 V short circuit diagnostic code is probably caused by a short circuit or an open circuit in the harness. The next probable cause is a sensor and the least probable cause is the ECM.

Troubleshooting Section

Illustration 15 The sensor for the intake manifold pressure

Illustration 16 Engine oil pressure sensor

g00884730

g00835146

92 Troubleshooting Section

Illustration 17 Schematic of the +5 V supply for the engine pressure sensors

Test Step 1. Inspect Electrical Connectors And Wiring.

A. Thoroughly inspect the following connections:

P1/J1 ECM Engine harness connector

•

P20/J20 MIC Machine harness connector

•

P201/J201 Engine oil pressure sensor

•

P200/J200 Intake manifold pressure sensor

•

Refer to Troubleshooting, “Electrical Connectors

- Inspect” for details.

g00954290

Troubleshooting Section

Illustration 18

B. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector that are associated with the +5 V sensor supply:

P1-14 Intake Manifold Pressure

•

P1-24 Engine Oil Pressure

•

P1-26 +5 V

•

P1-34 Sensor Common

•

Refer to Illustration 18.

C. Check the ECM connector (Allen head screw) for

the proper torque of 6.0 N·m (55 lb in).

D. Check the harness and wiring for abrasion and

pinch points from the sensors back to the ECM.

Expected Result:

All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.

g00954709

Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check for Active Diagnostic Codes.

A. Connect the electronic service tool to the data

link connector.

B. Turn the keyswitch to the ON position while the

engine is OFF.

C. Monitor the active diagnostic code screen on the

electronic service tool. Check and record any active diagnostic codes.

Note: Wait at least 15 seconds in order for the diagnostic codes to become active.

Expected Result:

Results:

OK – Proceed to Test Step 2.

•

Not OK

•

Select the condition of the following codes:

262-03 5 Volt Sensor Power Supply, voltage more

•

tha normal

94 Troubleshooting Section

262-04 5 Volt Sensor Power Supply, voltage less

•

than normal

Results:

Active – Proceed to Test Step 3.

•

Logged ONLY – Proceed to Test Step 5.

•

Not Active or Logged – The +5 V supply is

•

operating correctly at this time. STOP.

Test Step 3. Disconnect The ECM Engine Harness Connector From The ECM.

A. Connect the electronic service tool to the

diagnostic connector.

Batteries give off flammable fumes which can explode.

To avoid injury or death, do not strike a match, cause aspark, or smoke in the vicinity of a battery.

NOTICE Do Not connect the bypass harness to the battery until the 20 Amp 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.

B. Turn the keyswitch to the OFF position while the

engine is off.

Troubleshooting Section

Illustration 19

C. Refer to Troubleshooting, “Engine Wiring

Information” for wiring instructions.

D. Disconnect J1/P1 ECM engine harness

connector .

E. Connect the J1 bypass harness to the ECM

connector.

F. Remove the fuse F1 from the bypass harness

and from the battery circuit.

G. Connect the unswitched battery cables directly

to the battery terminals.

H. Install the F1 fuse to the in-line fuse holder.

Note: The bypass harness directly connects the keyswitch circuit to the ECM. The ECM will have power until the connection to the + battery cable is disconnected. Remove the “F1” fuse from the in-line fuse holder in order to isolate the ECM.

I. Turn the keyswitch to the ON position while the

engine is off.

g00954711

262-04 5 Volt Sensor Supply voltage less than

•

normal

Note: When ECM engine harness connector J1/P1 is disconnected and the keyswitch is in the ON position, open circuit diagnostic codes will be “Active” or “Logged” for all of the engine sensors. This is normal.

Expected Result:

The +5 V diagnostic code is active when the ECM engine harness connector is disconnected.

Results:

Ye s – The +5 V diagnostic code is active

•

when the ECM engine harness connector is disconnected.

J. Access the active diagnostic code screen on

the electronic service tool. Check for one of the following active diagnostic codes:

262-03 5 Volt Sensor Supply voltage more

•

than normal

96 Troubleshooting Section

Repair: Temporarily connect a test ECM to

the engine J20/P20. The test ECM should be programmed with the same values and with the same parameters as the suspect ECM. Recheck for a +5 V diagnostic code. If a +5 V diagnostic code is not active, the original ECM is faulty. Reconnect the original ECM and check the +5 V diagnostic codes. If a +5 V diagnostic code becomes active, replace the ECM. If the ECM is replaced, the new ECM should be programmed with the same values and with the same parameter as the suspect ECM.

STOP.

No – The +5 V sensor diagnostic code is no

•

longer active when the harness is disconnected. Either the harness or a sensor that is attached to the harness is causing the problem. Reconnect the ECM engine harness connector. Proceed to Test Step 4.

Test Step 4. Disconnect The +5 V Sensors While Active Diagnostic Codes Are Being Monitored.

A. Connect the electronic service tool to the

diagnostic connector.

Expected Result:

The original +5 V diagnostic code remains active.

Results:

Ye s – The +5 V diagnostic code is still active. The

•

harness is the cause of the problem. Leave the sensors disconnected. Proceed to Test Step 5.

No – The +5 V diagnostic code is not active

•

when a specific sensor is disconnected.

Repair: Reconnect the sensor that is suspected of causing the problem. If the problem returns after the reconnection of the sensor, disconnect the sensor. If the problem disappears after the disconnection of the sensor, replace the sensor.

Clear all diagnostic codes. Verify that the repair eliminates the problem.

STOP.

B. Turn the keyswitch to the ON position while the

engine is OFF.

C. Access the active diagnostic code screen on

the electronic service tool. Verify that one of the following diagnostic codes is active:

262-03 5 Volt Sensor Supply voltage more

•

than normal

262-04 5 Volt Sensor Supply voltage less than

•

normal

D. Disconnect the following sensors one at a time:

Engine oil pressure sensor J201/P201

•

Intake manifold pressure sensor J200/P200

•

E. Wait for 30 seconds after each pressure sensor

is disconnected while the electronic service tool is being monitored in order to verify that the disconnection of a specific sensor deactivates the +5 V diagnostic code.

Note: When the sensors are disconnected and the keyswitch is in the ON position, open circuit diagnostic codes will be active or logged when the +5 V diagnostic codes are no longer active. This is normal. Clear these diagnostic codes after this test step is completed.

Test Step 5. Check the Engine Harness.

Troubleshooting Section

Illustration 20

A. Turn the keyswitch to the OFF position while the

engine is OFF.

B. Disconnect ECM connector J1/P1. Verify that

all of the +5 V engine pressure sensors that are attached to the ECM connectors are disconnected.

Engine oil pressure sensor J201/P201

•

Intake manifold pressure sensor J200/P200

•

C. Measure the resistance from P1-26 +5 V

Engine Pressure Sensor to each of the following terminals:

P1:14 Intake manifold Pressure

•

P1:24 Engine Oil Pressure

•

a. Wiggle the harness during the measurement

in order to reveal any intermittent short condition.

Expected Result:

g00954709

Results:

OK – The +5 V line is not shorted in the engine

•

harness. Ensure that the engine harness is connected to the ECM and that all of the sensors are reconnected. There does not appear to be a problem at this time. Clear all diagnostic codes. Continue to troubleshoot until the original condition is resolved. STOP.

Not OK

•

Repair: Replace the engine harness. Clear all logged diagnostic codes. Verify that the repair eliminates the problem.

STOP.

i01798196

Air Inlet Heater Circuit - Test

System Operation Description:

Each resistance measurement is more than 20 ohms.

The air inlet heater is a cold starting aid.

Use this procedure under the following circumstances:

Check voltage for the air inlet heater starting aid.

•

98 Troubleshooting Section

Check the operation of the air inlet heater starting

•

aid.

Also use this procedure if another procedure has directed you here.

The air inlet heater starting aid is used to improve the engines’ ability to start when the engine is cold. A reduction of white smoke is also a benefit of the air inlet heater starting aid.

The ECM controls the operation of the air inlet heater starting aid through the air inlet heater relay and P1:43.

There are two types of air inlet heater starting aid that equip 1100 Series engines. The 1104 uses glow plugs. The 1106 uses a fuelled starting aid.

Illustration 21 Schematic for the air inlet heater starting aid

g00878524

Troubleshooting Section

Illustration 22 ECM pin locations for air inlet heater starting aid

g00878757

Illustration 23 MIC pin locations for the air inlet heater starting aid

g00954741

100 Troubleshooting Section

Test Step 1. Inspect Electrical Connectors and Wiring

A. Thoroughly inspect the J1/P1 ECM connector and

J20/P20 MIC. Inspect the terminal connections on the air inlet heater relay. Refer to Troubleshooting, “Electrical Connectors - Inspect” for details.

B. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector that are associated with the air inlet heater starting aid. Refer to Illustration 22 and 23.

C. Check the ECM connector (Allen head screw) for

the proper torque of 6.0 N·m (55 lb in).

D. Check the harness and wiring for abrasion and

for pinch points from the sensors back to the ECM.

Expected Result:

All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.

Expected Result:

The battery voltage is correct.

Results:

OK – Proceed to Test Step 3.

•

Not OK – There is a problem in the wires between

•

the battery and the air inlet heater starting aid.

Repair: Check the fuse and wires. Repair the wires or replace the fuse. Verify that the repairs have eliminated the problem.

STOP.

Test Step 3. Check the Output from the Power Relay for the Air Inlet Heater Starting Aid

A. Turn the ignition key switch to the ON position.

Refer to Illustration 21.

B. Measure the voltage between the following

contacts:

Results:

OK – The wiring and the connectors are good.

•

Proceed to Test Step 2.

Not OK – There is a problem with the wiring and

•

the connectors.

Repair: Perform the following repair:

Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check the Supply to the Power Relay for the Air Inlet Heater Starting Aid

A. Turn the ignition key switch to the ON position.

Refer to Illustration 21.

B. Measure the resistance between the following

contacts:

A The supply side of the air inlet heater power

•

relay and NEG battery

C Positive side of the air inlet heater relay coil

•

and NEG battery

(B)

•

NEG battery

•

Expected Result:

The battery has the proper voltage.

Results:

OK – There is a problem in the wires between the

•

relay and the air inlet heater starting aid.

Repair: Repair the wires or replace the wires. Verify that the repair has eliminated the problem.

STOP.

Not OK – Proceed to Test Step 4.

•

Test Step 4. Ground the Input to the Power Relay at the MIC

A. Turn the keyswitch to the OFF position.

B. Disconnect P20 connector from the MIC and

connect a 70 pin Breakout T.

C. Connect the electronic service tool to the

diagnostic connector.

D. Turn the keyswitch to the ON position.

101

Troubleshooting Section

E. Use the override setting in the electronic service

tool in order to engage the air inlet heater starting aid.

F. Measure the voltage between P20:43 air inlet

heater control and socket 69 NEG battery on the Breakout T.

Expected Result:

The voltage is 0 volts when the air inlet heater starting aid is engaged.

Results:

OK – Proceed to Test Step 5.

•

Not OK – The problem is in the wires between

•

the power relay for the air inlet heater starting aid and the MIC.

Repair: Repair the harness or replace the harness. Verify that the repair has eliminated the problem.

STOP.

Test Step 5. Ground the Input to the Power Relay at the ECM connector

A. Turn the ignition key switch to the OFF position.

B. Remove the 70 pin Breakout T and reconnect

the P20 MIC.

C. Disconnect the P1 ECM connector from the ECM

and connect a 70 pin Breakout T.

D. Connect the electronic service tool to the

diagnostic connector.

Repair: Repair the damaged wire or replace the wire. Verify that the problem has been eliminated.

If the repair has not eliminated the problem proceed to test step 6.

STOP.

Test Step 6. Override the Air Inlet Heater Starting Aid in order to Test the ECM

A. Turn the ignition key switch to the OFF position.

B. Remove the 70 pin Breakout T.

C. Connect the P1 ECM connector.

D. Connect the electronic service tool to the

diagnostic connector.

E. Turn the keyswitch to the ON position.

F. Use the electronic service tool to monitor the

status screen.

G. Use the override parameter for the air inlet heater

starting aid to override the following systems:

Glow plug starting aid (if equipped)

•

Fuelled starting aid (if equipped)

•

H. Verify that the air inlet heater starting aid is either

“enabled” or “disabled”.

I. Verify that the lamp for the air inlet heater starting

aid is on.

Expected Result:

E. Turn the keyswitch to the ON position.

F. Insert a jumper wire between J1:43 on the

Breakout T. Monitor the status screen on the electronic service tool. Slowly connect and disconnect the other end of the jumper wire to socket 69 NEG battery on the Breakout T.

Expected Result:

When the jumper wire is connected the status of the relay should be closed.

When the jumper wire is disconnected the status of the relay should be open.

Results:

OK – Proceed to Test Step 6.

•

Not OK – The problem is in the wire harness

•

between the MIC and the ECM connector.

The air inlet heater starting aid is working properly.

Results:

OK – The ECM is operating properly. STOP.

•

Not OK – The ECM is not working properly.

•

Repair: Temporarily connect a test ECM. Remove all jumpers and replace all connectors. The test ECM should be programmed with the correct software. All parameters should be set to the same value of the suspect ECM.

If the problem is eliminated with the test ECM, reconnect the suspect ECM. If the problem returns with the suspect ECM, replace the suspect ECM.

Verify that the repair has eliminated the problem.

STOP.

Perkins Engine 1104 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual