Perkins Engine 1104E, 1106E Troubleshooting

Troubleshooting

RENR2696-01

March 2005

1104E and

R F11 -U p ( Engine) RH11-Up ( R K 11- U p ( Engine) VK11-Up (Engine)

Engine)

1106E Engines

i01658146

Important Safety Information

Most accidents t basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necess

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate o read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Be

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations th this publication.

hat involve product operation, maintenance and repair are caused by failure to observe

ary training, skills and tools to perform these functions properly.

r perform any lubrication, maintenance or repair on this product, until you have

, bodily injury or death could occur to you or to other persons.

come Alert! Your Safety is Involved.

at may cause product damage are identified by “NOTICE” labels on the product and in

Perkins cannot anticipa te e ver y p os sible c irc u mstance t hat m ight invol ve a pote n ti al hazard . The warnings proc edure, work me thod or ope rating technique tha t is not s pecific ally rec ommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product w repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was availabl measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you s t ar t any jo

in this publication and on the product are, therefore, not all inclusive. If a tool,

ill not be damaged or be made unsafe by the operation, lubrication, maintenance or

e at the time that the publication was written. The specifications, torques, pressures,

b . Perkins dea le rs hav e t he m os t c ur r en t i nfo rm ati on a va il abl e.

When replacement parts are required for this product Perkins re comme nds usi ng Perkins

e ment parts or parts w ith equiva lent

re pl ac specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

RENR2696-01 3

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 ..................................... 32

Factory Passwords ............................................... 32

Flash Programming .............................................. 32

System Configuration Parameters

System Configuration Parameters ........................ 34

Troubleshooting without a Diagnostic Code

Alternator Noise (Noisy Operation) ....................... 35

Alternator Will Not Charge (Charging Problem) .... 35

Battery .................................................................. 35

Can Not Reach Top Engine RPM ......................... 36

Coolant in Engine Oil ............................................ 38

Coolant Temperature Is Too High ......................... 39

ECM Will Not Accept Factory Passwords ............. 40

ECM Will Not Communicate with Other Systems or

Display Modules .................................................. 40

Electronic Service Tool Will Not Communicate with

ECM .......................... .......................................... 40

Engine Cranks but Will Not Start .......................... 41

Engine Has Early Wear ........................................ 43

Engine Misfires, Runs Rough or Is Unstable ........ 43

Engine Oil in Cooling System ............................... 46

Engine Speed Does Not Change .......................... 46

Engine Stalls at Low RPM .................................... 47

Engine Vibration ................................................... 48

Engine Will Not Crank ........................................... 49

Excessive Black Smoke ........................................ 50

Excessive Engine Oil Consumption ...................... 51

Excessive Valve Lash ........................................... 52

Excessive White Smoke ....................................... 53

Intake Air Temperature Is Too High ...................... 54

Intermittent Engine Shutdown ............................... 55

Intermittent Low Power or Power Cutout .............. 56

Low Engine Oil Pressure ...................................... 58

Low Power/Poor or No Response to Throttle ....... 59

Mechanical Noise (Knock) in Engine .................... 61

Noise Coming from Cylinder ................................. 61

Poor Acceleration or Response ............................ 62

Troubleshooting with a Diagnostic Code

CID 0041 FMI 03 8v Sensor Power Supply, Voltage

More Than Normal .............................................. 64

CID 0041 FMI 04 8v Sensor Power Supply, Voltage

Less Than Normal ............................................... 64

CID 0091 FMI 02 Throttle Demand Sensor Erratic Or

Intermittent .............. ............................................ 6

CID 0091 FMI 03 Throttle Demand Sensor Open

Circuit Or Shorted High ....................................... 65

CID 0091 FMI 04 T

Low ..................................................................... 65

CID 0091 FMI 08 Throttle Demand Sensor Abnormal

Signal .................................................................. 66

CID 0091 FMI 12 Throttle Demand Sensor Out Of

Calibration ....................................... .................... 66

CID 0100 FMI 03

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

CID 0100 FMI 04 Engine Oil Pressure Sensor

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

CID 0100 FMI 10 Engine Oil Pressure Sensor, Power

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

CID 0102 FMI 03

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

CID 0102 FMI 04 Intake Manifold Pressure Sensor

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

CID 0102 FMI 10 Intake Manifold Pressure Sensor

Power Suppl y Open Circuit ................................. 68

CID 0105 FMI 03

Sensor Open Circuit Or Shorted High ................. 69

CID 0105 FMI 04 Intake Manifold Temperature

Sensor Shorte

CID 0110 FMI 03 Engine Coolant Temperature

Sensor Open Circuit Or Shorted High ................. 69

CID 0110 FMI 04

Sensor Shorted Low ........................................... 70

CID 0174 FMI 02 Fuel Temperature Sensor Erratic,

Intermittent

CID 0247 FMI 09 J1939 Datalink, Abnormal

Update ................................................................ 71

CID 0253 FMI 02 CID 0262 FMI 03 5v Sensor Power Supply, Voltage

More Than Normal .............................................. 71

CID 0262 FMI 04

Less Than Normal ............................................... 72

CID 0266 FMI 02 Incorrect Crank-without-inject

inputs .................................................................. 72

CID 0320 FMI 02 Speed And Timing Sensor

Intermittent Loss Of Signal .................................. 73

CID 0320 FMI 11

Signal .................................................................. 73

CID0342FMI02SpeedAndTimingSensorNo.2

Intermittent CID 0774 FMI 02 Throttle Demand Sensor No.2

Erratic Or Intermittent .......................................... 74

CID 0774 FMI 03

Open Circuit Or Shorted High ............................. 74

CID 0774 FMI 04 Throttle Demand Sensor No.2

Shorted Low ........................................................ 7

CID 0774 FMI 08 Throttle Demand Sensor No.2

Abnormal Signal .................................................. 75

CID 0774 FMI 12

Of Calibration ...................................................... 75

CID 1627 FMI 03 Fuel Injection Pump Relay Did Not

Turn Off ............................................................... 76

CID 1684 FMI 00 Fuel Injection Pump, Fuel

Temperature More Than Normal ......................... 76

CID 1684 FMI 02

Failure ................................................................. 77

hrottle Demand Sensor Shorted

Engine Oil Pressure Sensor Open

Intake Manifold Pressure Sensor,

Intake Manifold Temperature

d Low ........................................... 69

Engine Coolant Temperature

.......................................................... 70

Incorrect ECM Software ........... 71

5v Sensor Power Supply, Voltage

Speed And Timing Sensor Loss Of

Signal ............................................... 73

Throttle Demand Sensor No.2

Throttle Demand Sensor No.2 Out

Fuel Injection Pump, Software

4 RENR2696-01 Table of Contents

CID 1684 FMI 03 Fuel Injection Pump, Fuelling

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

CID 1684 FMI 04 Fuel Injection Pump, Supply

Voltage Fault ....................................................... 77

CID 1684 FMI 05 F

Width ................................................................... 78

CID 1684 FMI 07 Fuel Injection Pump, Mechanical

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

CID 1684 FMI 08 Fuel Injection Pump, Crankshaft

Reference Faul t .................................................. 79

CID 1684 FMI 09

Fault .................................................................... 80

CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff

Signal Error ......................................................... 8

CID 1684 FMI 11 Fuel Injection Pump, Internal

Sensor Fault ........................................................ 81

CID 1684 FMI 12

Failure ................................................................. 81

CID 1684 FMI 14 Fuel Injection Pump, No

Communicatio

CID 1743 FMI 02 Engine Speed Mode Selection

Switch State, Invalid State .................................. 83

CID 1894 FMI 02

Switch State, Invalid State .................................. 83

CID 1895 FMI 02 Set Speed Control Speed Toggle

Switch, Inval

uel Injection Pump, Invalid Pulse

Fuel Injection Pump, CAN

Fuel Injection Pump, Device

ns ................................................. 82

Set Speed Control Disengage

id State ............................................ 83

Engine Temperature Sensor Open or Short Circuit -

Test ................................................................... 171

Fuel Injection Pump Circuit - Test ....................... 178

Indicator Lamp Circuit - Test ............................... 195

Mode Selection

Set Speed Circuit - Test ...................................... 204

Throttle Switch Circuit - Test ............................... 212

Circuit - Test .............................. 198

Index Section

Index ................................................................... 221

Troubleshooting with an Event Code

Event Codes ........................................................ 85

E015 High Engine Coolant Temperature Derate .. 85 E016 High Engine Coolant Temperature

Shutdown ............................................................ 85

E017 High Engine Coolant Temperature

Warning ............................................................... 85

E025 High Intak

E027 High Intake Air Temperature Warning ......... 86

E040 Low Engine Oil Pressure Shutdown ............ 86

E054 High Fuel T

E056 High Fuel Temperature Warning .................. 88

E100 Low Engine Oil Pressure Warning ............... 89

E190 Engine Ove E442 Engine Failed to Stop with a No-Fuel

Command ........................................................... 90

E883 Engine Fai

Disengaged ......................................................... 91

Diagnostic Fun

5 Volt Engine Pressure Sensor Supply Circuit -

Test ..................................................................... 92

Air Inlet Heate

Analog Throttle Position Sensor Circuit - Test .... 104

CAN Data Link Circuit - Test ................................ 113

Data Link Circu

Digital Throttle Position Sensor Circuit - Test ..... 126

Electrical Connectors - Inspect ........................... 135

Electrical Powe

Engine Oil Level Switch Circuit - Test ................. 152

Engine Pressure Sensor Open or Short Circuit -

Test ................................................................... 157

Engine Speed/Timing Sensor Circuit - Test ........ 164

e Air Temperature Derate ............ 86

emperature Derate .................... 87

rspeed Warning ........................ 90

led To Stop When Fuel Solenoid

ctional Tests

r Circuit - Test ................................. 99

it - Test ......................................... 118

r Supply Circuit - Test ................. 146

RENR2696-01 5

Troubleshooting Section

Electronic Troubleshooting

i01798100

System Overview

System Opera

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

designed for electronic control. The

ion of engine sensors. The ECM

sors. The software contains parameters

arameters.

tion

6 RENR2696-01 Troubleshooting Section

Electronic Controls

Illustration 1

g00908788

RENR2696-01 7

Troubleshooting Section

Illustration 2

The e lectronic 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 RENR2696-01 Troubleshooting Section

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

n of the number 1 cylinder from the

e top dead center position. The ECM

then forces fuel to flow to the fuel

the best control of exhaust emissions.

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 air pressure and engine rpm. The FRC Limit is used to control the air/fuel ratio in order to control the engine’s e a higher intake manifold air pressure, the ECM increases the FRC Limit. A higher intake manifold air press 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 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.

a limit that is based on intake manifold

xhaust emissions. When the ECM senses

ure indicates that there is more air in the

Fuel Limit enables the engine power and

Diagnostic Codes

When the ECM detects an engine problem, the ECM generates a diagnostic code. Also, the ECM logs the dia the problem’s occurrence. The ECM also logs the number of occurrences of the problem. There are two typ codes and event codes.

Diagno

Diagnostic fault codes are provided in order to indic problem has been detected by the ECM. In some cases, the engine performance can be affected when the co frequently, the operator cannot detect any difference in the engine performance.

gnostic code in order to indicate the time of

es of diagnostic fault codes. There are fault

stic Fault Codes

ate that an electrical problem or an electronic

ndition that is causing the code exists. More

If the operator indicates that a performance problem occurs, the dia of the problem. Use either a laptop computer or a hand held diagnostic tool to access the diagnostic codes. The pro

If the operator does not indicate a problem with theenginepe logged by the ECM. This situation indicates that the ECM detected an abnormal engine condition, but the abnor 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 ver

The ECM is indicating an active code at the

•

present tim

gnostic code may indicate the cause

blem should then be corrected.

rformance and a diagnostic code is

mal condition did not affect engine

y short period of time.

Diagnostic Event Codes

Diagnostic event codes are used to indicate that some operational problem has been detected in the engine electronic malfunction.

by the ECM. This does not indicate an

Programmable Parameters

Certain pa may be changed with electronic service tools. The parameters are stored in the ECM, and the parameter by passwords. These parameters are System Configuration Parameters.

System Configuration Parameters are set at the factory. System Configuration Parameters affect emission passwords must be obtained and factory passwords must be used to change the System Configuration Paramet

Passwor

System Configuration Parameters are protected by factory on a computer system that is available only to Perkins distributors. Since factory passwords contain alphab tool may change System Configuration Parameters. System Configuration Parameters affect the power rating

Refer to Troubleshooting, “Programming Parameters” and Tro

rameters that affect the engine operation

s are protected from unauthorized changes

s or power ratings within the engine. Factory

ers.

passwords. Factory passwords are calculated

etic characters, only an electronic service

or the emissions.

ubleshooting, “Factory Passwords”.

RENR2696-01 9

Troubleshooting Section

i01798101

Glossary

Active Diagnostic Code – An active diagnostic

code alerts the 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

Before Top Dead Center (BTC) – BTDC is the 180 degrees o 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 an 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 harnes engine harness. This connection allows a normal circuit operation and the connection simultaneously provides a signals.

Bypass Cir

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 othe application, the CAN Data Link connects the ECM to the Electronic Fuel Injection Pump.

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

Cold Mode

and for cold engine operation that includes timing that is retarded and low idle that is raised. This mode is u emissions and faster warm up time.

Communi

communication adapter provides a communication link between the ECM and the Electronic Service Too l .

Component Identifier (CID) – The CID is a number

entifies the specific component of the electronic

that id control system that has experienced a diagnostic code.

operator or the service technician that

is reoccurring.

f crankshaft rotation before the piston

d atmospheric pressure is commonly

s that is designed to connect into the

Breakout T in order to measure the

cuit – A bypass circuit is a circuit that is

r microprocessor based devices. In this

– Cold mode is a mode for cold starting

sed for engine protection, reduced smoke

cation Adapter Tool – The

Coolant Level Sensor – The coolant level sensor

detects the abs probe. The sensor then sends a signal to the ECM.

Coolant Tempe

temperature sensor detects the engine coolant temperature for cold mode operation and for Engine Monitoring.

Data Link – The Data Link is a serial communication portthatisu microprocessor based devices.

Desired Engi

is input to the electronic governor within the ECM. The electronic governor uses the signal from the throttle pos 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 electroni

Diagnostic Lamp – A diagnostic lamp is sometimes called the 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 modu with +8 VDC from the ECM.

Digital S

the ECM is used in order to power the digital sensors.

Direct Cu

current that flows consistently in only one direction.

DT, DT Con

of connector that is used on Perkins engines. The connectors are manufactured by Deutsch.

Duty Cycle – Refer to “Pulse Width Modulation”.

Electron

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

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

on under all conditions. The electronic engine

ence or presence of coolant at the

rature Sensor – The coolant

sed for communication with other

ne Speed – The desired engine speed

ition sensor, the engine speed/timing

c system malfunction.

check engine light. The diagnostic lamp

lated signal. Digital sensors are supplied

ensor Supply – The+8VDCsupplyfrom

rrent (DC) – Direct current is the type of

nector, or Deutsch DT – This is a type

ic Engine Control – The electronic

10 RENR2696-01 Troubleshooting Section

Electronic Control Module (ECM) – The ECM is the control c provides power to the electronics. The ECM monitors data that is input from the sensors of the engine. The ECMactsasago and the power of the engine.

Engine Monit

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 sen sensor sends the signal to the ECM.

Engine Speed

speed/timing sensor provides a variable amplitude and pulse width modulated signal to the ECM. The ECM interpr and the engine speed.

Event Code

in order to indicate an abnormal engine operating condition. These codes usually indicate a mechanical problem in

Failure Mode Identifier (FMI) – This identifier indicates 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 electr of replacing components.

Fuel Rati

is based on the control of the ratio of the fuel to air. The FRC is used for purposes of emission control. When the 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 monitor thecalculatedfuelrateaccordingly.

Full Loa

that represents the fuel system adjustment. This adjustment is made at the factory in order to fine tune the fue is stamped on the engine information ratings plate. This parameter must be programmed.

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

s the fuel temperature and the ECM adjusts

l system. The correct value for this parameter

ammed.

omputer of the engine. The ECM

vernor in order to control the speed

oring – Engine Monitoring is the part

sor measures engine oil pressure. The

/Timing Sensor – The engine

ets this signal as the crankshaft position

– An event code may be activated

stead of an electrical system problem.

the type of failure that has been experienced

onic service tool over the data link instead

o Control (FRC) – The FRC is a limit that

ECM senses a higher intake manifold

d Setting (FLS) – The FLS is the number

Harness – The harness is the bundle of wiring

(loom) that con system.

Hertz (Hz) – He frequency in cycles per second.

Intake Manifo

intake manifold air temperature sensor detects the air temperature in the intake manifold. The ECM monitors 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 press pressure). This difference in air pressure can be caused by variable air velocity within the manifold. The differe by an increase in air pressure by a turbocharger (if equipped). The sensor for the intake manifold air pressu 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 th without the electronic controls.

J1939 CAN

diagnostic communications data link that is used to communicate between the ECM and the electronic service t

Logged Dia gnostic Codes – Logged diagnostic codes ar These codes are meant to be an indicator of possible causes for intermittent problems. Refer to the term “Di information.

MAB – Thi 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 or a connection that is broken. When this condition exists, the signal or the supply voltage can no longer reach

Parameter – A parameter is a value or a limit that is pro characteristics or behaviors of the engine.

agnostic Code” in this glossary for more

by an open switch, or by an electrical wire

the intended destination.

grammable. This helps determine specific

nects all components of the electronic

rtz is the measure of electrical

ld Air Temperature Sensor – The

air temperature and other data in the

ure outside the engine (atmospheric

nce in pressure can also be caused

re measures the difference between

esystem.Theenginewillnotoperate

Data Link – This data link is a SAE

ool.

e codes which are stored in the memory.

s is a Bosch acronym for the fuel shutoff

RENR2696-01 11

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) f

or the ECM and the module contains the performance maps for a specific engine. The personality module may be reprogrammed through flash progr

amming.

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 p

osition.

Pulse Width Modulation (PWM) – The PWM is a signal tha

t 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 c

ircuit 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 e

ventually 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 asensortoth

eECM.

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 Conf

iguration Parameters – System

configuration parameters are parameters that affect emissions and/or operating characteristics of the engine.

Throttle Position – Thethrottlepositionisthe interpret

ation 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 P

osition Sensor – The throttle position

sensor is an electronic sensor that is connected to an accelerator pedal or a hand lever. This sensor sends aPWMsign

al 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.

TopDeadCenter –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.

Tot al Tattletale – The total tattletale is the total number of changes to all the parameters that are stored i

ntheECM.

Voltage Load Protection Module (“VLPM”) – The “VLPM” m

onitors the voltage of the electronic system. The “VLPM”will eliminate any high voltage conditions that occur. The “VLPM” will protect the fuel injection pump fr

om any high voltage conditions that could

damage the pump.

12 RENR2696-01 Troubleshooting Section

i01798102

Electronic Service Tools

Electronic Service Tools are designed to help the service techni 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 a 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

•

cian with the diagnosis and repair of

re used to check the continuity of

Table 1

Required Electronic Service Tools for the Use

Part

Number

N/A

of the Electronic Service Tool

Description

Required

IBM compatible PC with 266 MHz Pentium processor

64 MB of RAM 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® Windows 2000, XP, ME, 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® Windows 2000, XP, ME, NT 4.0, or 98 RS232 port with 16550AF UART

Engine configuration

•

The electron

icservicetoolcanbeusedbythe

technician to perform the following functions:

Diagnostic

•

Sensor calibrations

•

Flash programming

•

Set paramet

•

tests

ers

The following components are required to use the electronic

service tool to service the engine.

RENR2696-01 13

Troubleshooting Section

Connecting the Electronic Service Tool and the Communi

cation 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.

Table 2

Optional Service Tools

Part Number Description

N/A Suitable Digital Multimeter

N/A Suitable Breakout T (70 pin)

N/A Suitable Cri

N/A Suitable Cylinder Pressure Indicator

N/A Suitable Battery Load Tester

mp Tool

Illustration 4

(1) Personal computer (PC) (2) Adapter Cable (Computer Se rial 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”.

02270470

Diagnostic Codes

his list identifies the respective faults for the CID

T FMI and the J Code FMI codes. The CID FMI codes are displayed on a laptop computer. The J Code FMI

odes are displayed on a Diagnostic Code Reader.

c 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 RENR2696-01 Troubleshooting Section

Table 3

CID FMI Code J Code FMI Code

0041 03 J0678 03

8V Sensor Powe

r Supply, voltage more than normal

0041 04 J0678 04 8V Sensor Power Supply, voltage less than normal

0091 02 J0091 02 Throttle Demand Sensor, erratic or intermittent

0091 03 J0091 03 Throttle Demand Sensor, open circuit or shorted high

0091 04 J0091 04

0091 08 J0091 08

0091 12 J0091-12

0100 03 J0100 03

0100 04 J0100 04

0100 10

0102 03 J0102 03

0102 04 J0102 04

0102 10

Throttle Demand Sensor, shorted low

Throttle Demand Sensor, abnormal signal

Throttle Demand Sensor, power supply failure

Engine Oil Pressure Sensor, open circuit or shorted high

Engine Oil Pressue Sensor, shorted low

Engine Oil Pressure Sensor, power supply open circuit

Intake Manifold Pressure Sensor, open circuit or shorted high

Intake Manifold Pressure Sensor, shorted low

Intake Ma

nifold Pressure Sensor, power supply open circuit

0105 03 J0105 03 Intake Manifold Temperature Sensor, open circuit or shorted high

0105 04 J0105 04 Intake Manifold Temperature Sensor, shorted low

0110 03 J0110 03 Engine Coolant Temperature Sensor, open circuit or shorted high

0110 04 J0110 04

Engine Coolant Temperature Sensor, shorted low

0168 02 J0168 02 Battery Voltage, intermittent or incorrect

0174 02 J0174 0

Fuel Temperature Sensor, erratic or intermittent

0247 09 J0639 09 J1939 Datalink, abnormal update

0253 02 J0234 02 Incorrect ECM Software

0262 0

0262 04 J0620 04

0266 02

0267 02

0320 02 J0637 02

0320 11 J0637 11

0321 02

0342 02 J0723 02

0590 02

0774 02

J0620

5V Sensor Power Supply, voltage more than normal

5V Sensor Power Supply, voltage less than normal

Crank without injection, switch state incorrect

External Stop Switch, data erratic or incorrect

Speed and Timing Sensor, intermittent loss of signal

Speed and Timing Sensor, loss of signal

Diagnostic Reset Switch, intermittent or incorrect

Speed and Timing Sensor No.2, intermittent signal

ECM identified missing timing pulse

rottle Demand Sensor No.2, erratic or intermittent

0774 03 Throttle Demand Sensor No.2, open circuit or shorted high

0774 04 Throttle Demand Sensor No.2, shorted low

74 08

0774 12

1627 03

1639 09

1684 00 J1077 00

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

Fuel Injection Pump, fuel temperature more than normal

Fault Description

(continued)

RENR2696-01 15

Troubleshooting Section

(Table 3, contd

1684 02 J1077 02 Fuel Injection Pump, software failure

1684 03 J1077 03

1684 04 J1077 04

1684 05 J1077 05 Fuel Injection Pump, invalid pulse width

1684 07 J1077 07

1684 08 J1077 08

1684 09 J1077 09

1684 10 J1077 10

1684 11 J1077 11

1684 12 J1077 12

1684 14 J1077 14 Fuel Injection Pump, no communications

1690 08

1743 02

1894 02

1895 02

Event Cod

E015 110 16 High Engine Coolant Temperature Derate

E016 110 00 High Engine Coolant Temperature Sutdown

E017 110 15 High Engine Coolant Temperature Warning

E025 105 16 High Intake Air Temperature Derate

E027 105 15 High Intake Air Temperature Warning

E039 100 18

E040 100 01 Low Engine Oil Pressure Shutdown

E054 174 16 High Fuel Temperature Derate

E056 174 15 High Fuel Temperature Warning

E100 100 17

E190 190 15

E442

E883 Engine Failed To Stop When Fuel Solenoid Disengaged

)

Fuel Injection Pump, fuelling fault

Fuel Injection Pump, supply voltage fault

Fuel Injection Pump, mechanical fault

Fuel Injection Pump, crankshaft reference fault

Fuel Injection Pump, CAN fault

Fuel Injection Pump, fuel shutoff signal error

Fuel Injection Pump, internal sensor fault

Fuel Injection Pump, device failure

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

CID FMI Co

Low Eng

Low Engine Oil Pressure Warning

Engine Overspeed Warning

Engi

ine Oil Pressure Derate

ne Failed To Stop With A No-Fuel Command

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 RENR2696-01 Troubleshooting Section

Use the lamps to

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

Each lamp will ways in order to identify the engine’s operational status. The lamps will also be illuminated in a combination 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 t

Table 4

Orange

lamp

(status)

ON ON

Refer to the

comments.

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

be illuminated in a combination of

of ways to indicate if the engine has a

he cold starting aid is required.

Red lamp

(status)

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

OFF ThelampwillbeOFFunless

thecoldstartingaidis required.

Comments

Table 6

Orange

lamp

(status)

OFF OFF

ON ON

Red lamp

(status)

Comments

There are no apparent problems.

The lubricating oil pressure 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.

Table 7

Orange

lamp

tatus)

OFF OFF No faults were detected.

ON OFF An electrical fault was

OFF

Red lamp

(status)

detected.

Flashing The engine was activated

when a serious fault was detected.

Comments

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.

Table 5

Orange

lamp

(status)

ON OFF The status of the lamps

Then OFF OFF This is the status of the

Red lamp

(status)

Comments

withthecoldstartingaidstill 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.

RENR2696-01 17

Troubleshooting Section

Table 8

Orange

lamp

(status)

OFF OFF No faults were detected.

OFF ON

Flashing

OFF

ON OFF An electrical fault has been

ON ON

Flashing ON The oil pressure is low and

Red lamp

(status)

OFF

Flashing

Comments

The oil pressure is low.

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

Either a fault has caused the engine to be shut down or the engine has exceeded the condition for a derate.

detected.

The oil pressure is low and thereisanelectricalfault.

Either a fault has caused the engine to engine has exceeded the conditions for a derate. There is also a

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

automatically

shut down or the

n electrical fault.

Usethelampstoidentifyactive diagnostic codes.

Table 9

CID

number

0041

0091

0100

0102

0105

0110

0174 Fuel Temperature Sensor 165

0247 J1939 Data

0253 Personality Module 416

0262

0320

0342 Secondary Engine Speed

0774

1684 Fuel Injection Pump 158

1743

1894 Cruise Control Status Switch 427

1895 Toggle Switch for Cruise

8 Volt Power Supply

Throttle Position Sensor

Engine Oil Pressure Sensor

Intake Manifold Pressure Sensor

Intake Manifold Air Temperature Sensor

Engine Coolant Temperature Sensor

5 Volt Power Supply

Engine Sp

Sensor

Secondary Throttle Position Sensor

Mode Selector Switch for Engine Operation

Control Speed

Description Flash

Link

eed/Timing Sensor

code

517

154

157

135

133

168

514

516

141

142

155

144

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 RENR2696-01 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 s is flashed.

The sequence o restarted at any time by reactivating the cycling of the keyswitch.

econds before the next active code

f flashing the active codes may be

i01798103

Replacing the ECM

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

The engine is Module (ECM). The ECM contains no moving parts. Follow the troubleshooting procedures in this manual in order to b 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 replacemen Troubleshooting, “Electrical Power Supply Circuit Tes t ”.

AtestECMcanbeusedinordertodetermineif the ECM on the engine is faulty. Install a test ECM in place of module into the test ECM. Program the parameters for the test ECM. The parameters must match the param following test steps for details. If the test ECM resolves the problem, reconnect the suspect ECM. Verify th replace the ECM.

equipped with an Electronic Control

e sure that replacing the ECM will correct

t of the ECM is attempted. Refer to

the suspect ECM. Flash the personality

eters in the suspect ECM. Refer to the

at the problem returns. If the problem returns,

Note: When a new ECM is not available, you may need to remove a service. The ECM must have the same serial number suffix. Ensure that the replacement ECM and the Personality M ECM. Be sure to record the parameters from the replacement ECM. Use the “Copy Configuration ECM Replacement

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.

n ECM from an engine that is not in

odule Interlock Code match the suspect

” function in the electronic service tool.

NOTICE

Use the e in the suspect ECM. Record the parameters in the suspect ECM. The personality module can be flashed into th e engine, the parameters must be programmed into the new ECM.

lectronic service tool to read the parameters

new ECM. After the ECM is installed on the

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.

a. Usetheoldmountinghardwaretoinstallthe

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

RENR2696-01 19

Troubleshooting Section

b. Check that the ECM mounting hardware is

installed corr used to protect the ECM from excessive vibration. The ECM should be able to drift in the rubber gro

c. Install the ground strap for the ECM on the

engine.

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

ECM. Tighten connectors to a torque of 6 N·m (55 lb in).

6. Download the

a. Connect the electronic service tool to the

service conn

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

the electron

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 c factory password when the electronic service tool is first connected. Activating the “Test ECM” mode will also cl

8. Use the electronic service tool to program the parameter

a. If the “Copy Configuration” procedure was

successfu Replacement” function to load the configuration file into the ECM.

ectly. The rubber grommets are

mmets.

the Allen head screw on the

Flash file.

ector.

ic service tool.

lear the rating interlock, enter the

ear the rating interlock.

s. Perform the following procedure.

l, use the “Copy Configuration, ECM

Diagnostic Code – When a problem with the electronic sys 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 requir active codes prior to servicing logged codes.

Logged Code –

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 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 of the code. If the system is powered, it is possible to generate an active diagnostic code whenever a component reconnected, the code is no longer active. Logged codes may be useful to help troubleshoot intermittent problems. the performance of the engine and the electronic system.

tem is detected, the ECM generates a

e immediate attention. Always service

Every generated code is stored in

, an event code will be generated if the

have been resolved since the logging

is disconnected. When the component is

Logged codes can also be used to review

b. If the “Copy Configuration” procedure failed,

configure the parameters individually. The paramete step 2.

9. Check for passwords are required to clear Logged Events.

rs should match the parameters from

logged diagnostic codes. Factory

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

•

Event

•

20 RENR2696-01 Troubleshooting Section

i01798105

Sensors and Electrical Connectors

Illustration 5

1104

Typical example of left side sensor locations

g00954205

RENR2696-01 21

Troubleshooting Section

ion 6

Illustrat

1104 engine

Typical location of the VLPM

g00915379

tration 7

Illus

1104

Typical example of right side sensor locations

g00882117

22 RENR2696-01 Troubleshooting Section

Illustration 8

1106

Typical example of left side sensor locations

g00884570

RENR2696-01 23

Troubleshooting Section

Illustration 9

1106 engine

Typical location of the VLPM

g00908929

24 RENR2696-01 Troubleshooting Section

Illustration 10

Typical example of right side sensor locations

1106

g00954214

RENR2696-01 25

Troubleshooting Section

Table 10

Connector

J1/P1 ECM Connector

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 Mani

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)

Function

70 Pin Machine

fold Air Temperature

Illustration 11

Basic engine schematic

g00

954204

26 RENR2696-01 Troubleshooting Section

i02294251

Engine Wiring Information

The wiring diagrams are revised periodically. The wiring diagram harness. For the most current information, always check the revision number of the diagram. Use the diagram with t

s will change with updates to the wiring

he latest revision number.

Illustration 12

Schematic for the fuel injection pump and ECM power supply for engines with a Machine Interface Connector that has 70 pins

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

Note: Some engines with a Machine Interface Connector that has 70 pins do not have the following wiring connections: 35, 50, 53, 54, 60, 62, 63, 64,

and 67. Note: Digital outputs 7,8,9,10,11,12,13, and 14 are only suitable for a 12 V system.

Machine Interface Connector

Two types of Machine Interface Connector are available. One type of connector has 70 pins and the other type has 31 pins. Illustration 13 and illustration 14 show the layout for the Machine Interface Connector with 70 pins. Illustration 15 and illustration 16 show the layout for the Machine Interface Connector with 31 pins.

g01152042