Perkins Engine 1104E, 1106E Troubleshooting

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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

RENR2696-01 27

Troubleshooting Section

Illustration 13

g00955504

28 RENR2696-01 Troubleshooting Section

Illustration 14

g00955499

RENR2696-01 29

Troubleshooting Section

Illustration 15

1152386

30 RENR2696-01 Troubleshooting Section

Illustration 16

g01152104

RENR2696-01 31

Troubleshooting Section

The procedures in this manual refer to the connector that has 70 pins

. Table 11 shows the conversion from engine models that have a connector with 70 pins to engine models that have a connector with 31 pins.

Table 11

Machine Interface Connector Pin Numbers

70 Pin 31 Pin

2 13

3 14

4 15

11 24

12 10

13 11

16* 27*

18 18

19 22

20 25

22 23

23 12

25 19

28 21

29 29

30 26

31 6

36 9

37 28

42 3

44 17

45 20

48 8

52 30

56 1

58 4

61 31

68 2

69* 1*

70 5

* These connections are not used on some

ine models.

eng

HarnessWireIdentification

Perkins identifies all wires with eleven solid colors. The circuit number is stamped on the wire at a 25 mm (1 inch) spacing. Table 12 lists the wire colors and the color codes.

Table 12

Color Codes for the Harness Wire

Color Code Color Color Code Color

BK Black GN Green

BR Brown BU Blue

RD Red PU Purple

OR Orange GY Gray

YL Yellow WH White

PK Pink

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.

32 RENR2696-01 Troubleshooting Section

Programming Pa

rameters

i01798107

Programming Parameters

Theelectronicservicetoolcanbeusedtoview 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

Passwords a to prevent unauthorized reprogramming of certain parameters. Passwords prevent unauthorized erasing of factory to control access to engine calibration parameters. Passwords allow the customer to control access to c

Factory P

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

re part of a security system that helps

logged events. Passwords allow the

ertain programmable engine parameters.

asswords

tory passwords are required to change

l. When the correct factory passwords have

Note: The old interlock code is required to change the interlock c code is also required to change the interlock code onausedECM.

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 numbe

•

Reason Code

•

Total Tattletale number

•

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

ode on a used ECM. A new interlock

r for the electronic service tool

ory passwords may only be used

ic service tool screen. A different set of

Customer Passwords

Customer Passwords allow the customer to restrict access to parameters that are programmable by the customer. T 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 parameter passwords. By using factory passwords, one can read customer passwords. Then use those customer password protected by customer passwords.

he customer passwords cannot be longer

s that are protected by customer

s to program parameters that have been

i01798110

In order certain information must be given to an authorized Perkins distributor. Since the factory passwords contain tool can be used to perform this function. In order to obtain the factory passwords, proceed as if you alr point, if the factory passwords are actually needed, the electronic service tool will request the factory passwo the information that is required to obtain the factory passwords.

to obtain the proper factory passwords,

alphabetic characters, the electronic service

eady have the factory passwords. At some

rds and the electronic service tool will display

Flash Programming

Flash Programming – This is a method of

programming or updating the personality module in an ECM.

Theelectronicservicetoolcanbeutilizedtoflash a new personality module into the ECM. The flash is accomplished by transferring the data from a PC to the ECM.

RENR2696-01 33

Troubleshooting Section

Flash Programm

ing 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

Selector” window will appear. Select the appropriate ECM that needs to be flashed and press “Brows

The “Flash File Selection” window will appear.

4. Theflashfilesarelocatedonadiskdriveandin

a directory. Select the correct disk drive and the correct dire the electronic service tool.

Alistoffla

5. Select the correct file from the list of flash files.

Read the “Fi to verify that the correct file is selected. Select “OK”.

ctory from “Drives” and “Directories” on

sh files will appear.

le Info” and the “Description” in order

been detected, the “ECM

e”.

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 diagno

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

b. Access the “Configuration” screen under

the “Servi the parameters that require programming. Look under the “Tattletale” column. All of the paramete more. If a parameter has a tattletale of 0, program that parameter.

stic code of 253-02 Incorrect

ce”menuinordertodetermine

rs should have a tattletale of 1 or

“WinFlash” Error Messages

If you rec programming, click on the “Cancel” button in order to stop the process. Access the information about the “ECM Make sure that you are flashing the correct file for your engine.

eive any error messages during flash

Summary” under the “Information” menu.

34 RENR2696-01 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.

When an ECM is replaced this rating interlock code must match the c 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, fue 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 i dealer for further information.

odethatisstoredintheECM.Ifthe

l injectors, and other components.

s rerated. Please contact the local OEM

“Engine Serial Number”

“Full Load Setting”

“Full Load Setting” is a number that represents the adjustment to the fuel system that was made atthefactoryinordertofinetunethefuelsystem. 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.

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.

WhenanewEC number in the ECM is not programmed. The “Engine Serial Number” should be programmed to match the engine ser information plate.

M is delivered, the engine serial

ial number that is stamped on the engine

“ECM Software Release Date”

This para and this parameter is not programmable. The “ECM SoftwareReleaseDate”isusedtoprovidethe version o and the software change levels can be monitored by this date. The date is provided in the month and the year (NOV is the year (1999).

meter is defined by the rating interlock

f the software. The Customer parameters

99). NOV is the month (November). 99

RENR2696-01 35

Troubleshooting Section

Troubleshooti

ng 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

Alternator Will Not Charge (Charging Problem)

Note: This is N

Probable Caus

Alternator drive belts

•

Charging circuit

•

Regulator

•

Alternator

•

Recommended Actions

Alternator Drive Belts

1. Inspect the co

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

OT an electronic system problem.

ndition of the alternator drive belts.

lternator - Remove” and Disassembly

i01798098

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 ten Adjust the belt tension if the tension is incorrect. Refer to Testing and Adjusting, “V-Belt - Test”.

sion on the alternator drive belts.

Charging Circuit

Inspect the b the charging circuit. Clean all connections and tighten all connections. Replace any faulty parts.

attery cables, wiring, and connections in

Alternator or Regulator

Verify that correctly. Refer to Testing and Adjusting, “Alternator

- Test”. The alternator is not a serviceable item. The alternator operating correctly.

the alternator or the regulator is operating

must be replaced if the alternator is not

i01798112

Battery

Note: This is NOT an electronic system problem.

Probable Causes

Faulty battery

•

Auxiliary device drains the battery current.

•

36 RENR2696-01 Troubleshooting Section

Recommended Ac

tions

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 th

ebatteryisabletomaintainacharge.

i01798113

Can Not Reach Top Engine RPM

Recommended Ac

tions

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing wi

th this procedure.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Tes

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

3. Check the die 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 Te s t ” .

t”.

ems Operation, Testing and

sel fuel for contamination. Refer to

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 l as h

•

Low compression (cylinder pressure)

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

ECM parameters

•

Throttle signal from the throttle position sensor

•

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 ch

gauge may be faulty.

9. If the engin water in the fuel.

10. Ensure tha OPEN position.

11. If the temp for solidified fuel (wax).

12. If the repa proceed to “Air Intake and Exhaust System”.

Air Intake

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

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

eck the fuel tank for fuel. The fuel

e has a water separator, check for

t the fuel supply valve is in the full

erature is below 0 °C (32 °F), check

irs do not eliminate the problem

and Exhaust System

3. Check the a

the following defects:

Blockages

•

Restrictions

•

ir intake and the exhaust system for

RENR2696-01 37

Troubleshooting Section

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 engin

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

2. Individuall injection nozzle. If there is no reduction in the engine speed refer to “Check the Turbocharger (if equippe

3. If all cylinders have been checked and no problems we

e speed at a fast idle, loosen the

ed. Tighten the high pressure fuel

y repeat this procedure for each fuel

d)”.

re detected proceed to “Valve Lash”.

Damaged cylinder head

•

Checking the Fuel Injection Nozzles

1. Remove the fuel

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)”.

injection nozzles from the cylinder

Check the Tu rbocharger (if equipped)

Note: The tur

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.

bochargers that are equipped on 1100

Valve Lash

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

necessary. Refer to Systems Operation, Testing and Adjusti Adjust”.

2. If the repai “Check for Low Compression”.

Check for L

1. Remove the fuel injection nozzles and perform a

compressi Testing and Adjusting, “Compression - Test ”data.

2. Make all ne

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 pi

•

ng, “Engine Valve Lash - Inspect and

r does not eliminate the fault proceed to

ow Compression

on test. Refer to Systems Operation,

cessary repairs to the engine.

ston rings

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

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

4. Check the turbocharger for worn bearings. Refer to Systems O “Turbocharger - Inspect”.

5. Check that 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, Te s t i ng a n

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

9. If the faul

“ECM Pa rameters”.

ECM Param

1. Ensure that the problem is not a programmed

paramete

ed.

peration, Testing and Adjusting,

the turbine blades rotate freely on the

d Adjusting, “Turbocharger - Inspect”.

t has not been eliminated proceed to

eters

Worn cylinder bores

•

Worn valves

•

Faulty cy

•

linder head gasket

2. Ensure that the correct mode was selected by using the

3. Use the electronic service tool to verify the correct engine ra

electronic service tool.

ting for the engine.

38 RENR2696-01 Troubleshooting Section

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

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

6. Ensure that the repairs have eliminated the performance p

7. If the repairs have not eliminated the faults proceed to “Ch Position Sensor ”.

Check the Sig

speed limit.

the OEM specifications.

roblems.

eck the Signal for the Throttle

nal for the Throttle Position

Sensor

1. Use the elect

signal for the throttle position sensor.

2. If the signal “Throttle Position Sensor Circuit - Test”.

3. If the engin Troubleshooting, “Throttle Switch Circuit - Test”.

ronic service tool and observe the

is erratic, refer to Troubleshooting,

ehasathrottleswitchreferto

Coolant in Engine Oil

i01798114

3. Remove the oil filter element or elements. Fit a new engine oil f crankcase with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual, “Engi information.

Cylinder Hea

1. Remove the cylinder head. Refer to Disassembly

and Assembly correct procedure.

2. Inspect the c signs of leakage.

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

4. If all of the cylinder liner projections were correct, and if there 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 gaske

ilter element or elements. Fill the

ne Oil and Filter - Change” for more

d Gasket

, “Cylinder Head - Remove” for the

ylinder head gasket for faults and any

inder liner projection. Refer to

ect.

was no obvious signs of a faulty head

t, fit a new head gasket.

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.

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.

6. To fit a new cylinder head gasket, refer to Disassemb Install” for the correct procedure.

Cylinder H

Check the cylinder head for flatness. Refer to Systems O correct procedure.

Check for found, repair the cylinder head and/or replace the cylinder head. Refer to Disassembly and Assembly, “Cylinde

If the cylinder head is flat and if the cylinder head is not crack for the Cylinder Block.

Cylinde

Inspect the cylinder block for cracks. If a crack is found, r block.

ly and Assembly, “Cylinder Head -

ead

peration, “Cylinder Head - Inspect” for the

cracks in the cylinder head. If a crack is

r Head - Install” for the correct procedure.

ed then refer to the recommended actions

rBlock

epair the cylinder block or replace the cylinder

RENR2696-01 39

Troubleshooting Section

i01798115

Coolant Temperature Is Too High

Note: This is n

Refer to Testing and Adjusting for information on determining t

Probable Caus

Radiator fins

•

Coolant level

•

Radiator cap a

•

Combustion gases in the cooling system

•

Engine cooling fan

•

Water tempera

•

Restriction in the coolant system

•

Coolant temperature gauge

•

ot an electronic system problem.

he cause of this condition.

nd/or pressure relief valve

ture regulators

3. Check that the seating surfaces of the pressure relief valve an undamaged.

Combustion Ga

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

d the radiator cap are clean and

ses in the Cooling System

l working temperature. Remove

f bubbles are present in the coolant,

action for the cylinder head gasket

d action for checking flatness of the

he coolant.

Water Temperature Regulator

Check the water temperature re gulator for correct operation. Refer to Testing and Adjusting, “Cooling System” fo replace the water temperature regulator. Refer to Disassembly and Assembly, “Water Temperature Regulato

r the proper procedure. If necessary,

r - Remove and Install” for more information.

Coolant pump

•

Excessive load on the system

•

Recommended Actions

Radiator Fins

Check the rad Remove any dirt and/or debris and straighten any bent fins.

Coolant Level

1. Inspect the c

coolant.

2. Check the coo leaks immediately.

Radiator Ca Valve

1. Pressure te

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

iator fins for dirt, debris, and/or damage.

oolant level. If necessary, add

ling system for leaks. Repair any

p and/or Pressure Relief

st the cooling system. Refer to Testing

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

he reading for the coolant temperature

Coolant Pump

Inspect and/or erosion. If necessary, repair the coolant pump or replace the coolant pump.

the impeller of the coolant pump for damage

Excessive Load on the System

Reduce t not reoccur.

he load and verify that the condition does

2. Check operation of the pressure relief valve and the radiator cap. If necessary, clean the component

s and/or replace the components.

40 RENR2696-01 Troubleshooting Section

i02270218

ECM Will Not Accept Factory Passwords

The connection of any electrical equipment and the disconnection of any electrical equipment may cause an expl jury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive at

Probable Cau

One of the following items may not be recorded correctly on

Passwords

•

Serial numbers

•

To t a l ta t t l e

•

Reason code

•

osion hazard which may result in in-

mosphere.

ses

the electronic service tool:

tale

i01798117

ECMWillNotCommunicate with Other Systems or Display Modules

Probable Causes

ECM

•

Electrical co

•

Data Link

•

Recommended Actions

1. Connect the electronic service tool to the

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

2. Ensure that the following items are correctly installed and undamaged. Refer to Troubles Inspect”.

nnectors

with the electronic service tool, refer

hooting, “Electrical Connectors -

Recommended Actions

1. Verify that the correct passwords were entered.

Check every character in each password. Remove the electri seconds and then retry.

2. Verify that “Factory Password” screen.

3. Use the elec following information has been entered correctly:

Engine seri

•

Serial number for the electronic control module

•

Serial number for the electronic service tool

•

To t a l ta t t

•

Reason code

•

cal power from the engine for 30

the electronic service tool is on the

tronic service tool to verify that the

al number

letale

J1/P1 ECM co

•

J20/P20 Machine interface connector

•

Wiring to display modules

•

Wiring to ot

•

3. Troubleshoot the Data Link for possible problems. Refer to Tro Te s t ” .

nnector

her control modules

ubleshooting, “Data Link Circuit -

i01798118

Electronic Service Tool Will Not Communicate with ECM

Probable Causes

The electr

•

configured.

The cables

•

connected correctly.

onic service tool is not correctly

to the electronic service tool are not

The electr

•

onic service is not functioning.

RENR2696-01 41

Troubleshooting Section

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 volta

•

Recommended A

Connect the communication adapter of the electronic service tool t Turn the ignition switch to the ON position. If the communication adapter for the electronic service tool activates, a 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 - Te

2. Change the electronic service tool components. Refer to Tro Test Step 6”.

ctions

o the PC and to the diagnostic connector.

nd the red power indicator lamp is ON,

st, Test Step 4”.

ubleshooting, “Data Link Circuit - Test,

Engine Cranks but Will Not Start

Probable Causes

Refer to the lo

•

Crank without injection (if equipped)

•

Starting motor or starting circuit

•

Val ve lash

•

Fuel injectors

•

Air inlet heater starting aid

•

Air intake and

•

Low compression (cylinder pressure)

•

Fuel supply

•

Recommended Actions

gged codes.

exhaust system

i02270216

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

4. If the electronic service tool cannot connect to the E CM the

4. Inspect the cable from the PC to the communic port has been used. Inspect the cable from the electronic service tool to the diagnostic connector. Change th 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 Test Step 3”.

6. Connect 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 anot “Data Link Circuit - Test, Test Step 7”.

ogram for the electronic service tool.

onic service tool reports “The interface

n proceed to step 5.

ation adapter. Verify that the correct PC

e electronic service tool components.

Troubleshooting, “Data Link Circuit - Test,

the electronic service tool directly

her battery . Proceed to Troubleshooting,

Diagnostic Co

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

Visual Check

1. Visually inspect the engine for the following faults:

Missing components

•

Damaged comp

•

Oil leaks

•

Coolant leaks

•

Fuel leaks

•

Hydraulic leaks

•

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

des

Troubleshoot any active codes before

onents

order to rotate the crankshaft.

42 RENR2696-01 Troubleshooting Section

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

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

Seized piston

•

Defects in the drive gears

•

Fluidinthecy

•

Improper timing of valves

•

or Starting Circuit”.

following problems:

linder bores

Crank Without Injection (If Equipped)

1. Check if the cr

connected.

2. If the crank wi connected, connect the normal running plug.

3. Check if the e

4. If the repairs do not eliminate the problem refer

to Troublesh

-Test”.

Starting M ot

ank without injection plug is

thout injection plug has been

ngine will start.

ooting, “Crank without Inject Circuit

or Solenoid or Starting

Circuit

1. Turn the keys

2. Check the positive battery and negative battery

connections

3. Perform a pull test on positive battery wires and negative ba “Electrical Connectors - Inspect”.

4. Check the ne ground stud.

witchtotheOFFposition.

to the ECM.

ttery wires. Refer to Troubleshooting,

gative battery connection on the

Valve lash

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

is necessary. Refer to Systems Operation, Testing and Adjusting Adjust”.

Ensure that th diagnostic codes before attempting to restart the engine.

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

, “Engine Valve Lash - Inspect and

e repairs have eliminated the active

Fuel Injectors

1. Remove the fu

head. Refer to Disassembly and Assembly, “Fuel Injectors - Remove”.

2. Check the fuel injectors. Refer to Systems Operation, Testing and Adjusting, “Fuel Injectors

-Test”.

3. If the repairs do not eliminate the problem proceed to “Air Inle

el injectors from the cylinder

t 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 o to Systems Operation, “Air Inlet Heater - Test”.

2. If the repai to “Air Intake and Exhaust System”.

Air Intake

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

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

f the air inlet heater starting aid. Refer

rs do not eliminate the problem proceed

and Exhaust System

5. Check the co

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 m

8. Check the operation of the starting switch. Refer to Trouble Circuit - Test”.

nnections of starting motor terminals.

otor and check the flywheel ring gear.

shooting, “Electrical power Supply

3. Check the a following defects:

Blockages

•

Restrictions

•

Damage to lines or hoses

•

4. Repair any the engine.

5. If the engi Compression”.

ir intake and exhaust systems for the

defects before attempting to restart

ne will not start proceed to “Low

RENR2696-01 43

Troubleshooting Section

Low Compression

1. Remove the fuel injectors and perform a

compression test. Refer to Systems Operations, Testing and Ad

Examples of low compression are shown in the following lis

Outside temperatures are too cold.

•

Mechanical problem

•

Faulty piston

•

Worn cylinder bores

•

Worn valves

•

Faulty cylind

•

Damaged cylinder head

•

2. Make all necessary repairs to the engine.

3. Ensure that th

diagnostic code.

4. If the engine

justing, “Compression - Test ”data.

rings

er head gasket

e repairs have eliminated the active

will not start proceed to “Fuel Supply”.

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Te

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

st”.

tems Operation, Testing and

11. If the temperature is below 0 °C (32 °F), check for solidified

12. Check the fuel injection pump. Refer to Troubleshoot Te s t ” .

fuel (wax).

ing, “Fuel Injection Pump Circuit -

i01798120

Engine Has Early Wear

Probable Caus

Dirt in engine oil

•

Leaks in air intake system

•

Low oil pressu

•

Recommended

Dirt in Engine Oil

1. Drain the oil from the crankcase and refill the

crankcase with clean engine oil. Install new engine oil filters. Manual for more information.

2. Check the oil spring or a broken spring. If the spring is weak or broken, replace the spring. Refer to Disassembly and Assembl information.

Leaks in Air

Refer to the Operation and Maintenance

Actions

filter bypass valve for a weak

y, “Engine Oil Filter Base” for more

Intake System

3. Check the di

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 Tes t ”.

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 c

gauge may be faulty.

9. If the engi water in the fuel.

10. Ensure tha in the full OPEN position.

esel fuel for contamination. Refer to

heck the fuel tank for fuel. The fuel

ne has a water separator, check for

t the fuel supply valve (if equipped) is

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

engine. Inspect the air intake system for

tem” for more information.

Low Oil Pressure

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:

44 RENR2696-01 Troubleshooting Section

Note: If the problem is intermittent and the problem cannot be dupli “Intermittent Low Power or Power Cutout”.

Note: If the pr conditions, test the engine under those conditions. Examples of certain conditions are high rpm, full load and engine op the symptoms under other conditions can give misleading results.

cated, refer to Troubleshooting,

oblem only occurs under certain

erating temperature. Troubleshooting

Probable Causes

Refer to the logged codes.

•

Fuel supply

•

Air intake and exhaust system

•

Individual malfunctioning cylinder

•

Valve l as h

•

Low compression (cylinder pressure)

•

Fuel injection nozzles

•

Air inlet hea

•

Engine speed/timing sensors

•

Throttle position sensor

•

Fuel injecti

•

ter starting aid

on pump

4. Check for air in the fuel system. Refer to Systems Operation, Tes Te s t ” .

5. Check that the properly.

6. Check for fuel

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 °C (32 °F), check for solidified fuel (wax).

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

ting and Adjusting, “Air in Fuel -

fuel lines are tight and secured

supply lines that are restricted.

Air Intake and Exhaust System

1. Check the air

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

3. Check the air intake and exhaust systems for the

following defects:

filter restriction indicator, if equipped.

Recommende

d 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 - T

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

3. Check the d Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

est”.

stems Operation, Testing and

iesel fuel for contamination. Refer to

Blockages

•

Restrictio

•

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 eng

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

2. Individua injectionnozzle.Ifthereisnotareductioninthe engine speed proceed to “Check the Air Inlet Heater Sta

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

ine speed at a fast idle, loosen the

peed. Tighten the high pressure fuel

lly repeat this procedure for each fuel

rting Aid”.

sh”.

RENR2696-01 45

Troubleshooting Section

Valve lash

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

is necessary. Refer to Systems Operation, Testing and Adjusting Adjust”.

2. If the repair d “Check for Low Compression”.

Check for Low C

Examples of low compression are shown on the following li

Mechanical problems

•

Faulty piston rings

•

Worn cylinder

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cyli

•

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

2. Make all nece

3. If the repair does not eliminate the fault proceed to

“Check the Fu

, “Engine Valve Lash - Inspect and

oes not eliminate the fault proceed to

ompression

st:

bores

nder head

test. Refer to Systems Operations,

ssary repairs to the engine.

el Injection Nozzles”.

Check the Fuel Injection Nozzles

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 cr speed. The other sensor is in the fuel injection pump in order to sense the pump’s internal timing wheel and speed. Th 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 co

2. Ensure that the connectors and cables for the engine speed correctly.

3. Check the wi that the cables to the sensors are not too tight. This could cause an intermittent problem due to vibration

4. If a fault with the engine speed/timing sensor is suspect Speed/Timing Circuit - Test”.

5. If a fault w not suspected proceed to “Check the Signal for the Throttle Demand Sensor”.

ankshaft position and the crankshaft

e sensor in the fuel injection pump

rrectly to the cylinder block.

/timing sensors are connected

ring harness in order to ensure

ed refer to Troubleshooting, “Engine

ith the engine speed/timing sensor is

Check the Signal for the Throttle Position Sensor

1. Use the electronic service tool and observe the

signal for the throttle position sensor.

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

2. Check the fuel injection nozzles. Refer to Systems Operation, Nozzle - Test”.

3. If the repai “Check the Air Inlet Heater Starting Aid”.

Check the A

1. Check for proper operation of the air inlet heater

starting a and Adjusting, “Electrical System”.

2. If the repa “Check the Engine Speed/Timing Sensors”.

ozzle - Remove”.

Testing and Adjusting, “Fuel Injection

rs do not eliminate the fault proceed to

ir Inlet Heater Starting Aid

id. Refer to Systems Operation, Testing

irs do not eliminate the fault refer to

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: Th

by the factory on the 1100 series engines are nonserviceable items. If any mechanical fault or any electri thenthefuelinjectionpumpmustbereplaced.

1. Use the e

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

e fuel injection pumps that are installed

cal fault occurs within the fuel injection pump

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

diagnostic fault codes.

46 RENR2696-01 Troubleshooting Section

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

Engine Oil in Co

Note: This is NOT an electronic system problem.

Refer to Testi determining the cause of this condition.

i01798122

oling System

ng and Adjusting for information on

Probable Causes

Engine oil coo

•

Cylinder head gasket

•

Cylinder head

•

ler core

Recommended Actions

Engine Oil Co

oler Core

5. If any of the cylinder liner projections were

incorrect, and the head gasket, fit a new head gasket. Refer to Disassembly and Assembly, “Cylinder Head Install” for t

Cylinder Head

1. Check the cylinder head for flatness. Refer to

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

2. Check the cylinder head for cracks. If a crack is found, repai the cylinder head. If the cylinder head is not cracked and the head is flat, fit the head. Refer to Disassemb Install” for the correct procedure.

Thoroughly remove all traces of the engine lubricating oil from the coolant system. Fill the coolant system with coolant. Refer to Op more information.

this had resulted in the failure of

he correct procedure.

rocedure.

r the cylinder head and/or replace

ly and Assembly, “Cylinder Head -

flush the coolant system in order to

eration and Maintenance Manual for

i01798123

1. Drain the coolant from the engine and the radiator. Drain the lub 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 proc cooler core. Refer to Disassembly and Assembly, “Engine Oil Cooler Core - Remove”. Fit new seals between the

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

Cylinder H

1. Remove the cylinder head. Refer to Disassembly

and Assemb correct procedure.

2. Inspect th signs of leakage.

3. Check the c 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 pr the Cylinder Head.

ricating engine oil from the engine oil

edure. If a leak is found, replace the oil

oil cooler and the oil cooler cover.

level. Refer to the Operation and

ead Gasket

ly, “Cylinder Head - Remove” for the

e cylinder head gasket for faults and any

ylinder liner projection. Refer to

oceed to the recommended actions for

Engine Speed Does Not Change

Note: Use t

does not change.

Probable Causes

Refer to lo

•

Throttle switch

•

Throttle position sensor

•

Engine spe

•

Recommend

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continui

If a problem with the throttle switch is suspected refer to Troubl

Refer to Troubleshooting, “Throttle Position Sensor Circuit are active.

his procedure only if the engine speed

gged codes.

ed/timing sensor

ed Repairs

ng with this procedure.

eshooting, “Throttle Switch Circuit - Test”.

Test” if any of the following diagnostic codes

RENR2696-01 47

Troubleshooting Section

91-08 Throttle Position Sensor Abnormal

•

774-08 Sec Throttle Position Signal Abnormal

•

41-03 8 Volt Sen

•

than normal

41-04 8 Volt Se

•

than normal

Refer to Troub Sensor Circuit - Test” if any of the following diagnostic codes are active.

320-02 Speed/Timing Sensor intermittent loss of

•

signal

320-11 Speed/Timing Sensor loss of signal

•

If there are no Troubleshooting Manual for your machine application.

sor Power Supply Voltage more

nsor Power Supply Volltage less

leshooting, “Engine Speed/Timing

active diagnostic codes refer to the

i01798124

Engine Stalls at Low RPM

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Tes

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

3. Check the dies 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 Te s t ” .

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 ch

gauge may be faulty.

t”.

ms Operation, Testing and

el fuel for contamination. Refer to

eck the fuel tank for fuel. The fuel

Probable Causes

Refer to logged codes.

•

Faulty fuel injection nozzles

•

Fuel supply

•

Accessory equipment

•

Power mode control (if equipped)

•

Recommended Actions

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”.

9. If the engin water in the fuel.

10. Ensure that in the full OPEN position.

11. If the tempe for solidified fuel (wax).

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

e has a water separator, check for

the fuel supply valve (if equipped) is

rature is below 0 °C (32 °F), check

NOTICE

the engine continuously for more than

Accessory Equipment

Check all a may create excessive load on the engine. Repair any damaged components or replace any damaged component

ccessory equipment for problems that

Power Mode Control (If Equipped)

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

Data Link Circuit - Test”.

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

”.

leshooting Manual for your engine

48 RENR2696-01 Troubleshooting Section

i01798125

Engine Vibration

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 supports

•

Malfunctioni

•

Valve l as h

•

Compression (cylinder pressure)

•

Fuel injectio

•

Turbocharger (if equipped)

•

Recommended Actions

ng individual cylinder

n nozzles

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

Valve Lash

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

valve lash if it is not correct. Refer to Systems Operation, Te Lash - Inspect and Adjust”.

2. If the repair d “Check for Low Compression (cylinder pressure)”.

Check for Low

sting and Adjusting, “Engine Valve

oes not eliminate the fault proceed to

Compression (cylinder

pressure)

1. Remove the fu

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,

el injection nozzles from the cylinder

“Compression - Test”.

Engine Supports

1. Start the engi

the speed range. Check for any of the following conditions:

Loose engine supports

•

Loose mounti

•

brackets

Loose bolts

•

Omitted bolts

•

2. Make all necessary repairs. Ensure that the repairs have eliminated the problem. If the vibration is Individual Cylinder”.

Malfunctio

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

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

ne and run the engine through

ng brackets or broken mounting

still present proceed to “Malfunctioning

ning Individual Cylinder

re fuel line to the fuel injection nozzle

fuel injection nozzle.

4. Ensure that the repairs have eliminated the problems.

5. If the problem has not been eliminated, proceed to “Check th

e 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

2. Check the fuel injection nozzles. Refer to Testing and Adjust

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Turboc

Nozzle - Remove”.

ing, “Fuel Injection Nozzle - Test”.

harger (if equipped)”.

Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100

Series engines are nonserviceable items. If any mechanic be replaced.

al fault exists then the turbocharger must

2. Individually repeat this procedure for each fuel injection engine speed proceed to “Check The Fuel Injection Nozzles”.

nozzle. If there is no reduction in the

1. Ensure th are tight.

at the mounting bolts for the turbocharger

RENR2696-01 49

Troubleshooting Section

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 Ope “Turbocharger - Inspect”. The turbochargers that are equipped on 1100 Series engines are not serviceable turbocharger must be replaced.

5. Check that th 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, Tes t in g a nd The adjustment of the wastegate is set at the factory. If the adjustment of the wastegate is incorrect

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

then the turbocharger must be replaced.

ration, Testing and Adjusting,

. If any mechanical fault exists then the

e turbine blades of the turbocharger

Adjusting, “Turbocharger - Inspect”.

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

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.

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

ty system is armed. Deactivate

Battery Cables and/or Batteries

1. Inspect the main power switch, battery posts,

and battery cables for loose connections and corrosion. I remove the battery cables and clean the battery cables. Clean the battery posts. Replace the cables. Tig

2. Inspect the batteries.

a. Charge the batteries.

f the battery cables are corroded,

hten any loose connections.

Engine Wil

lNotCrank

Probable Causes

Machine security system

•

Battery ca

•

Starting motor solenoid or starting circuit

•

Starting motor and/or flywheel ring gear

•

Electrica

•

Internal engine problem

•

bles and/or batteries

l power supply

Recommended Repairs

Machine Security System

1. Verify th

Turn the keyswitch to the ON position.

2. Use the el the 1639-09 Machine Security System is active. Verify that the lamp for the machine security system is

at the correct keyswitch is being used.

ectronic service tool in order to check if

on.

i01798126

b. Load test th

e batteries.

Starting Motor Solenoid or Starting Circuit

1. Test the operation of the starting motor solenoid.

Refer to Sys “Starting System”.

2. Check the w

tems Operation/Testing and Adjusting,

iring 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

2. Inspect the starter motor pinion and the flywheel ring gear f

, “System Starting”.

or damage.

Electrical Power Supply

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

Internal Engine Problem

1. Disassemble the engine. Refer to Disassembly

and Assembly.

2. Inspect the internal components for the following conditions:

50 RENR2696-01 Troubleshooting Section

Seizure

•

Broken components

•

Bent component

•

Excessive Black Smoke

Probable Causes

Air intake sys

•

Individual malfunctioning cylinder

•

Valve l as h

•

Low compressi

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

Broken 5 volt

•

theintakemanifold

ECM software

•

tem or exhaust system

on (cylinder pressure)

supply wire to the pressure sensor in

i01798127

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 cyl in engine speed. Tighten the high pressure fuel line to the fuel injection nozzle.

2. Individually repeat this procedure for each fuel injectionnozzle.Ifthereisnoreductioninthe engine speed Injection Nozzles”.

3. If there is a r “V alve Lash”.

inder. Note if there is any reduction

proceed to “Checking the Fuel

eduction in engine speed proceed to

Valve Lash

Ensure that the valve lash is correct. Reset the valve lash if it is n “Engine Valve Lash - Inspect/Adjust”.

If the repai “Low Compression (cylinder pressure)”.

Low Compres

Examples of low compression are shown in the following l

Mechanical problem

•

ot correct. Refer to Testing and Adjusting,

r does not eliminate the fault proceed to

sion (cylinder pressure)

ist:

Recommended

Actions

Air Intake System or Exhaust System

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

2. Ensure that t

3. Check the air intake and the exhaust system for

the followin

Blockages

•

Restrictions

•

Damage to the

•

hoses

4. Make all nec

5. If the problem has not been eliminated, proceed

to “Individ

he air filter is clean and serviceable.

gdefects:

air intake and exhaust lines and

essary repairs to the engine.

ual Malfunctioning Cylinder”.

Faulty piston rings

•

Worn cylind

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cyl

•

1. Remove the fuel injection nozzles and perform a compressi Testing and Adjusting, “Compression - Test ”data.

2. Make all ne

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”.

er bores

inder head

on test. Refer to Systems Operation,

cessary repairs to the engine.

Checking the Fuel Injection Nozzles

1. Remove the

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

fuel injection nozzles from the cylinder

RENR2696-01 51

Troubleshooting Section

2. Check the fuel injection nozzles. Refer to Testing and Adjusting,

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Check the T

“Fuel Injection Nozzle - Test”.

urbocharger (if equipped)”.

Check the Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100

Series engines are nonserviceable items. If any mechanical f be replaced.

1. Ensure that t are tight.

2. Check that th or restricted.

3. Check that th and debris.

4. Check the tu to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”. The turbochargers that are equippe serviceable. If any mechanical fault exists then the turbocharger must be replaced.

ault exists then the turbocharger must

he mounting bolts for the turbocharger

e turbocharger drain is not blocked

e turbocharger housing is free of dirt

rbocharger for worn bearings. Refer

d on 1100 Series engines are not

VerifyingtheECMSoftware

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 c

•

2. Use the electronic service tool to verify any active diagnostic co

3. If diagnostic codes are present, the ECM must be programmed wi

orrect software

des.

th the correct information.

i01798128

Excessive Engine Oil Consumption

Probable Causes

Oil level

•

Engine crankcase breather

•

5. Check that the turbine blades rotate freely on the turbocharger. Refer to Systems Operation, Testing and Adjust

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

7. Make all n

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”.

ing, “Turbocharger - Inspect”.

orrectly. Refer to Systems Operation,

If the adjustment of the wastegate is

ecessary repairs to the engine.

Broken 5 volt Supply Wire

1. Check the

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”.

5 volt supply for the intake manifold

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.

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.

52 RENR2696-01 Troubleshooting Section

3. Check the air intake and the exhaust system for the following d

Blockages

•

Restrictions

•

Damage to the a

•

hoses

4. Make all neces

5. Ensure that the repairs have eliminated the

diagnostic co

efects:

ir intake and exhaust lines and

sary repairs to the engine.

de.

Turbocharger (if equipped)

Note: The turbochargers that are equipped on 1100

Series engines are nonserviceable. If any mechanical fault exists t

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

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

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

hen the turbocharger must be replaced.

1. Remove the fuel injection nozzles and perform a compression te Testing and Adjusting, “Compression - Test ”data.

2. Make all neces

3. Ensure that the repairs have eliminated the faults.

Examples of low compression are shown in the following list:

Mechanical problem

•

Faulty piston

•

Worn cylinder bores

•

Worn valves

•

Faulty cylind

•

Damaged cylinder head

•

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

st. Refer to Systems Operation,

sary repairs to the engine.

rings

er head gasket

i01798129

Excessive Valve Lash

4. Check the turbocharger for worn bearings. Refer

to Systems O “Turbocharger - Inspect”. The turbochargers that are equipped on 1100 series engines are not serviceabl turbocharger should be replaced.

5. Check that 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, Tes t in g a n The adjustment of the wastegate is set at the factory. If the adjustment of the wastegate is incorrec

7. Make all necessary repairs to the engine.

8. Ensure that the repairs have eliminated the faults.

Low Compr

1. Verify that the valve lash is correct. Refer

to System Inspect/Adjust”.

peration, Testing and Adjusting,

e. If any mechanical fault exists then the

the turbine blades rotate freely on the

d Adjusting, “Turbocharger - Inspect”.

t then the turbocharger must be replaced.

ession (cylinder pressure)

s Operation, “Engine 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

•

Val ve 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.

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.

RENR2696-01 53

Troubleshooting Section

Valve Lash

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

ocedure.

Valve Train Components

1. Inspect the following components of the valve

train:

Rocker arms

•

Pushrods

•

Valve lifters

•

Camshaft

•

Valve s te m s

•

Rocker shafts

•

2. Check the components for the following conditions: abnormal wear, excessive wear, straightnes new parts for replacement.

Note: If the c must also be used.

3. Adjust the va Testing and Adjusting, “Engine Valve Lash Inspect/Adjust” for the correct procedure.

s, and cleanliness. If necessary, use

amshaft is replaced, new valve lifters

lve lash of the engine. Refer to

Engine pressure sensors

•

Recommended Actions

Fuel Supply

1. Check the fuel p

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

2. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, “F

3. Check the diesel fuel for contamination. Refer to Systems Oper Quality - Test”.

4. Check for air Operation, Testing and Adjusting, “Air in Fuel Te s t ” .

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

6. Check for fuel supply lines that are restricted.

7. Check the fu

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

gauge may be

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

ressure. Refer to Systems

uel System - Prime”.

ation, Testing and Adjusting, “Fuel

in the fuel system. Refer to Systems

el filters.

faulty.

fuel.

i01798130

Excessive White Smoke

Note: Some white smoke may be present during

cold start-up conditions when the engine is operating normally.Ifthewhitesmokepersists,theremaybe a problem.

Probable Causes

Fuel supply

•

Individual malfunctioning cylinder

•

Valve l as h

•

Low compression (cylinder pressure)

•

Air inlet heater starting aid

•

Fuel injection nozzles

•

Coolant temperature sensor circuit

•

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

11. If the temperature is below 0 °C (32 °F), check for solidi

PEN position.

fied fuel (wax).

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 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 “Fuel Injection Nozzles”.

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

cylinder. Note if there is any reduction

54 RENR2696-01 Troubleshooting Section

Valve Lash

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

Testing and Adjusting, “Engine Valve Lash Inspect/Adju correct.

2. If the repair d “Low Compression (cylinder p ressure)”.

Low Compressi

1. Remove the fuel injection nozzles and perform a

compression Testing and Adjusting, “Compression - Test ”data.

2. Make all nece

3. Ensure that the repairs have eliminated the faults.

Examples of low compression are shown in the following list:

Mechanical problem

•

Faulty pisto

•

Worn cylinder bores

•

Worn valves

•

st”. Rest the valve lash if it is not

oes not eliminate the fault proceed to

on (cylinder pressure)

test. Refer to Systems Operation,

ssary repairs to the engine.

n rings

4. If the problem has not been eliminated, proceed to “Coolant Tem

perature Sensor Circuit”.

Coolant Temperature Sensor Circuit

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 co Refer to Troubleshooting, “Engine Temperature Sensor Open or Short Circuit - Test”.

des for the coolant temperature.

Engine Pressure Sensors

1. Connect the e

diagnostic connector.

2. Monitor the d service tool in order to verify the presence of active diagnostic codes for the engine pressure sensors. Re Pressure Sensor Supply Circuit - Test”.

lectronic service tool to the

isplay screen on the electronic

fer to Troubleshooting, “5 Volt Engine

i01798131

Intake Air Temperature Is Too High

Faulty cylin

•

Damaged cylinder head

•

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

der head gasket

Air Inlet Heater Starting Aid

1. Verify that

Refer to Testing and Adjusting, “Air Inlet Heater

-Test”.

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

the air inlet heater is operating correctly.

Fuel Injection Nozzles

1. Remove the

head. Refer to Disassembly and Assembly, “Fuel InjectionNozzle-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.

fuel injection nozzles from the cylinder

Probable Causes

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.

RENR2696-01 55

Troubleshooting Section

Coolant Temperature

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

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 intak intake air temperature.

Measure the i engine is operating under load. For specific data, refer to the Technical Marketing Information for the engine.

Intake A ir 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 th for the altitude.

e manifold pressure. This increases

ntake manifold pressure while the

at the settings for the engine are correct

Check the pump for proper operation.

•

Makerepairs,ifnecessary.

•

Check for Suffi

cient Flow of Air Through

the Aftercooler (if equipped)

Determine the 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 aftercoo

Intermitten

Note: Use this procedure only if the engine shuts

down completely and the engine must be restarted.

pressure differential of the intake air

ler.

i01798132

t Engine Shutdown

Probable Causes

Refer to the logged codes.

•

Fuel supply

•

Check the In

take Manifold Air Temperature S ensor and/or the Circuit

Allow the intake manifold air temperature sensor to cool and remove the sensor. Check the reading for the int 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 i

ake air temperature. If the sensor is

s solved.

Check for Sufficient Coolant Flow Through t

Check the intake temperature of the coolant for the aftercoo temperature. If the temperature is OK, check the outlet temperature of the coolant. A high temperature differe

If there is a high differential between the intake tempera for the aftercooler, perform the following procedures:

Check th

•

obstructions.

he Aftercooler (if equipped)

ler. Compare the reading to the regulated

ntial indicates an insufficient flow rate.

ture and the outlet temperature of the coolant

e coolant circuit of the aftercooler for

Engine protection device (if equipped)

•

Electrical connectors

•

Recommended Actions

Logged Code

Check for any event and active diagnostic codes on the electro codes before continuing with this procedure.

nic service tool. Troubleshoot any active

Fuel Supply

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”.

NOTICE

56 RENR2696-01 Troubleshooting Section

4. Check for air in the fuel system. Refer to Systems Operation, Tes Tes t ”.

5. Check that the properly.

6. Check for fuel

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 °C (32 °F), check for solidified fuel (wax).

ting and Adjusting, “Air in Fuel -

fuel lines are tight and secured

supply lines that are restricted.

Engine Protection Device (if equipped)

1. Check if a war

2. Refer to Troubleshooting, “Indicator Lamp Circuit

-Test”.

ning lamp is ON.

2. Refer to Troubleshooting, “Electrical Connectors

- Inspect”.

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

4. Inspect the battery wires from the ECM back to the battery c Wiring Diagram. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refe Pump Circuit - Test” for more information.

5. Check the P40 to Troubleshooting, “Fuel Injection Pump Circuit

-Test”.

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

logged diagnostic code: 253-02

Circuit - Test”.

ompartment. Refer to the Engine

r to Troubleshooting, “Fuel Injection

VP30 fuel pump connector. Refer

i01798133

Intermittent Low Power or Power Cuto

3. Repair any faults and ensure that the engine

protection

4. If the fault has not been eliminated refer to “Electrica

device is not in operation.

l Connectors”.

Electrical Connectors

1. Check for correct installation of ECM connectors

at the following locations:,

J1/P1 ECM connector

•

J20/P20 Mac

•

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

•

connector

hine interface connector

Intake manifold pressure sensor

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

Probable Causes

Refer to the logged codes.

•

Electrica

•

Fuel supply

•

Intake manifold pressure

•

Air intake

•

ECM connection

•

Throttle position sensor

•

l connectors

and exhaust system

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.

P40 Fuel in

•

jection pump connector

RENR2696-01 57

Troubleshooting Section

Diagnostic Codes

Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing wi

th 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 h “Fuel Supply”.

as not been eliminated proceed to

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Pressure - Test”.

Testing and Adjusting, “Fuel System

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 inta

should read 0 kPa (0 Psi).

4. Use the electr following logged diagnostic codes:

102-03 Intake

•

circuit or shorted high

102-04 Intake

•

shorted low

If either of th proceed to Troubleshooting, “Engine Pressure Sensor Open or Short Circuit - Test”.

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

ke manifold pressure. The pressure

onic service tool to check for the

Manifold Pressure Sensor open

Manifold Pressure Sensor

ese diagnostic codes are logged,

Air Intake and Exhaust System

2. Ensure that

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 - Te

4. Check for air in the fuel system. Refer to Systems Operation Tes t ”.

5. Check that properly.

6. Check for f

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 °C (32 °F), check for solidified fuel (wax).

the fuel system has been primed.

st”.

, Testing and Adjusting, “Air in Fuel -

the fuel lines are tight and secured

uel supply lines that are restricted.

1. Check the air

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

3. Check the air intake and exhaust systems for the

following defects:

Blockages

•

Restrictio

•

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 “E CM Connection”.

filter restriction indicator, if equipped.

ECM Connection

1. Check that

connected.

2. Verify the connections and the ground connections for the Engine Control Module (ECM).

the J1/P1 connector is correctly

proper pin positions for the power

3. If a problem is suspected with the ECM power and ground connections refer to Troubleshooting, “Electric

al Power Supply Circuit - Test”.

58 RENR2696-01 Troubleshooting Section

4. Verify that the ECM connections for the power and ground conn connected properly.

5. If a fault is su pump power and ground connections refer to Troubleshooting, “Fuel Injection Pump Circuit Tes t ”.

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

7. If the repairs do not eliminate the faults, proceed to “Check the

ections at the fuel pump are

spected with the fuel injection

ted.

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 cali 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

6. Refer to Troubleshooting, “Throttle Position Circuit

-Test”.

bration (80 to 87%) at high idle if the

with more throttle.

i01798134

Piston cooling jets (if equipped)

•

Engine oil suction tube

•

Engine oil pump

•

Bearing clearance

•

Recommended Actions

Engine Oil Level

Inspect the en

Engine Oil Pressure Gauge

Check the actual engine oil pressure with a mechanical gauge. Compare the oil pressure reading from the elect mechanical gauge.

Engine Oil By

1. Remove the engine oil bypass valves and clean

the engine oi the oil filter base for the bypass valves. Refer to Disassembly and Assembly, “Engine Oil Filter Base - Disass

2. Install new engine oil filters. Refer to the Operation and Mainten

Piston Cooling Jets (if equipped)

Inspect the piston cooling jets for damage. Replace any piston cooling jet that appears to be cracked or broken. Ref Cooling Jets - Remove and Install” for the correct procedure.

gine oil level. If necessary, add oil.

ronic service tool t o the pressure on the

pass Valves

l bypass valves. Clean the bores in

emble”.

ance Manual for more information.

er to Disassembly and Assembly, “Piston

Low Engine

Do not oper Engine damage will result. If measured oil pressure is low, discontinue engine operation until the problem is correcte

ate the engine with low oil pressure.

Oil Pressure

NOTICE

Probable Causes

Engine oil level

•

Engine oi

•

Engine oil bypass valves

•

l pressure gauge

Engine Oil Suction Tube

1. Check the i

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 i

nlet screen on the oil suction tube

nto the supply to the oil pump.

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.

RENR2696-01 59

Troubleshooting Section

Bearing Clearance

Inspect the engine components for excessive bearing clearance. If necessary, replace the bearings and/or the component of the components that should be inspected for excessive bearing clearance:

Crankshaft main bearings

•

Connecting ro

•

Camshaft bearings

•

s. The following list is an example

d bearings

i01798135

Low Power/Poor or No Response to Throttle

Probable Causes

Refer to logged codes.

•

Fuel supply

•

Air intake and exhaust system

•

Individual cylinder problem

•

Valve l as h

•

Low compression (cylinder pressure)

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

Fuel Supply

1. Check the fuel pressure. Refer to Systems

Operation, Testing and Adjusting, “Fuel System Pressure - Tes

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

3. Check the dies 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 Te s t ” .

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 ch

gauge may be faulty.

9. If the engin water in the fuel.

10. Ensure that in the full OPEN position.

11. If the tempe for solidified fuel (wax).

12. If the repa proceed to “Air Intake and Exhaust System”.

t”.

ms Operation, Testing and

el fuel for contamination. Refer to

eck the fuel tank for fuel. The fuel

e has a water separator, check for

the fuel supply valve (if equipped) is

rature is below 0 °C (32 °F), check

irs do not eliminate the problem

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.

Diagnostic Codes

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

Air Intake

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

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

3. Check the a

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 tha

diagnostic code.

6. If the prob to “Individual Malfunctioning Cylinders”.

and Exhaust System

ir intake and the exhaust system for

t the repairs have eliminated the

lem has not been eliminated, proceed

60 RENR2696-01 Troubleshooting Section

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 cyl 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”.

inder. Note if there is any reduction

Valve Lash

1. Check the val

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 L

ve lash and reset the valve lash, if

ow Compression”.

Check for Low Compression

1. Remove the fuel injection nozzles and perform a

compression test. Refer to Systems Operation, Tes t in g a nd

2. Make all necessary repairs to the engine.

3. Ensure that the repairs have eliminated the faults.

4. If the repa

“Checking the Fuel Injection Nozzles”.

Examples o following list:

Adjusting, “Compression - Test”.

ir does not eliminate the fault proceed to

f low compression are shown in the

2. Check the fuel injection nozzles. Refer to Testing and Adjusting,

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated, proceed to “Check the T

“Fuel Injection Nozzle - Test”.

urbocharger (if equipped)”.

Check the Tu rbocharger (if equipped)

Note: The turbochargers that are equipped on 1100

Series engines are nonserviceable items. If any mechanical f be replaced.

1. Ensure that t are tight.

2. Check that th or restricted.

3. Check that th and debris.

5. Check that the turbine blades rotate freely on the turbocharger. Refer to Systems Operation, Testing and Adjust

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

ault exists then the turbocharger must

he mounting bolts for the turbocharger

e turbocharger drain is not blocked

e turbocharger housing is free of dirt

rbocharger for worn bearings. Refer

d to 1100 series engines are not

ing, “Turbocharger - Inspect”.

orrectly. Refer to Systems Operation,

If the adjustment of the wastegate is

Mechanica

•

Faulty piston rings

•

Worn cylinder bores

•

Worn valve

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

Checking t

1. Remove the fuel injection nozzles from the cylinder

head. Refe InjectionNozzle-Remove”.

l problem

he Fuel Injection Nozzles

r to Disassembly and Assembly, “Fuel

7. Make all n

8. Ensure that the repairs have eliminated the faults.

9. If the fault has not been eliminated proceed to

“ECM Pa rameters”.

ecessary repairs to the engine.

ECM Parameters

1. Ensure th

parameter.

2. Use the el correct mode was selected.

3. Use the e correct engine rating has been provided.

at the problem is not a programmed

ectronic service tool to ensure that the

lectronic service tool to verify that the

RENR2696-01 61

Troubleshooting Section

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

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

6. Ensure that the repairs have eliminated the performance p

7. If the repairs have not eliminated the faults proceed to “El

speed limit.

the OEM specifications.

roblems.

ectronic System Problem”.

Electronic System Problem

1. Ensure that the correct mode is selected.

2. Turn the start

3. Use the electronic service tool to verify that the

intake manifo the 5 V sensor supply for the intake manifold pressure. Refer to Troubleshooting, “5 Volt Engine Pressure Sen

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

switch to the ON position.

ld pressure is 0 kPa (0 psi). Check

sor Supply Circuit - Test”.

atus.

Recommended Ac

tions

Accessory Equipment

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

Repair the engine accessories and/or

Valve Train Components

Remove the val following items for damage: camshaft, valve springs, lifters, pushrods, and bridges. Thoroughly clean the valve train c replaced, also replace the valve lifters. Ensure that all of the valves move freely. Replace any damaged parts.

ve mechanism covers. Check the

omponents. If the camshaft is being

Connecting Rod and Main Bearings

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

. Replace any damaged parts.

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

6. If the maximum no-load speed can not be obtained refer to Tro

- Test” and Troubleshooting, “Mode Selection Circuit - Test”.

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

-Test”.

Mechanica

load speed.

ubleshooting, “Throttle Switch Circuit

i01798136

l Noise (Knock) in

Engine

Probable C

Accessory equipment

•

Valve train components

•

Connectin

•

auses

g rod and main bearings

i01798137

Noise C oming from Cylinder

Probable Causes

Fuel quality

•

Fuel injection nozzles

•

Val ve 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

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.

62 RENR2696-01 Troubleshooting Section

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 l as h

•

Low compression

•

Fuel injection nozzles

•

Turbocharger (if equipped)

•

ECM parameters

•

Intake manifold pressure (engines that are

•

turbocharged)

Recommended Repairs

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

Operation, Tes Te s t ” .

5. Check that the properly.

6. Check for fuel

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 °C (32 °F), check for solidified fuel (wax).

ting and Adjusting, “Air in Fuel -

fuel lines are tight and secured

supply lines that are restricted.

Individual Malfunctioning Cylinder

1. With the engi

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

2. Individual injection nozzle.

ne speed at a fast idle, loosen the

eed. Tighten the fuel line to the fuel

ly repeat this procedure for each fuel

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 t 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 - T

2. Ensure that the fuel system has been primed.

Refer to Sys Adjusting, “Fuel System - Prime”.

3. Check the di

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

he engine continuously for more than

est”.

tems Operation, Testing and

esel fuel for contamination. Refer to

3. If there is n proceed to “Check the Fuel Injection Nozzles”.

4. If there is “V alve Lash”.

o reduction in the engine speed

a reduction in engine speed proceed to

Valve Lash

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

necessary and Adjusting, “Engine Valve lash - Inspect and Adjust”.

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

. Refer to Systems Operation, Testing

Check for Low Compression

1. Remove th

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

2. Make all necessary repairs to the engine.

3. Ensure th

e fuel injection nozzles and perform a

at the repairs have eliminated the faults.

RENR2696-01 63

Troubleshooting Section

4. If the repair does not eliminate the fault proceed to “Check the Fuel

Examples of low compression are shown in the following lis

Mechanical problem

•

Faulty piston rings

•

Worn cylinder

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cylin

•

Injection Nozzles”.

bores

der head

Check the Fuel Injection Nozzles

1. Remove the fuel injection nozzles from the cylinder

head. Refer to Disassembly and Assembly, “Fuel Injection No

2. Check the fuel injection nozzles. Refer to Testing and Adjustin

3. Ensure that the repairs have eliminated the problems.

4. If the problem has not been eliminated,proceed to “Check the Tu

zzle - Remove”.

g, “Fuel Injection Nozzle - Test”.

rbocharger (if equipped)”.

Check the Turbocharger ( if equipped)

Note: The turbochargers that are equipped on 1100

Series are nonserviceable items. If any mechanical fault exist

1. Ensure that the mounting bolts for the turbocharger

s then the turbocharger must be replaced.

are tight.

6. Ensure that the wastegate on the turbocharger is adjusted corre Testing and Adjusting, “Turbocharger - Inspect”. The adjustment of the wastegate is set at the factory. If ad then the turbocharger must be replaced.

7. Make all nece

8. Ensure that the repairs have eliminated the faults.

9. If the fault has not been eliminated proceed to

“ECM Pa rameters”.

ctly. Refer to Systems Operation,

justment of the wastegate is required

ssary repairs to the engine.

ECM Parameters

1. Ensure that t

parameter.

2. Use the elect that the correct mode was selected.

3. Use the elect engine rating for the engine.

4. Use the elec maximum engine speed limit.

5. Use the elec parameters to the OEM specifications.

6. Ensure that performance problems.

7. If the repai proceed to “Check Intake Manifold Pressure”.

Check Inta

he problem is not a programmed

ronic service tool in order to ensure

ronic service tool to verify the correct

tronic service tool to verify the

tronic service tool to reset the

the repairs have eliminated the

rs have not eliminated the faults

ke Manifold Pressure (Engines

that are turbocharged)

1. Turn the st

art switch to the ON position.

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

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

4. Check the turbocharger for worn bearings. Refer to Systems “Turbocharger - Inspect”. The turbochargers that are equipped to 1100 series engines are not serviceab turbocharger must be replaced.

5. Check that turbocharger. Refer to Systems Operation, Testing and Adjusting, “Turbocharger - Inspect”.

ed.

Operation, Testing and Adjusting,

le. If any mechanical fault exists then the

the turbine blades rotate freely on the

2. Use the electronic service tool to observe the intake man pressure should be 0 kPa (0 psi).

ifold pressure. The intake manifold

64 RENR2696-01 Troubleshooting Section

The ECM reads signal voltage that is below normal.

Troubleshooti

ng with a

•

Diagnostic Code

i01798139

CID 0041 FMI 03 8v Senso r Power Supply, Voltage More Than Normal

Conditions Which Generate This Code:

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.

TheECMwillreturntheenginetolowidleorasafe speed. The engine will remain at low idle or safe speed while the diagnostic code remains active.

System Response:

The ECM will log code may be viewed on the electronic service tool.

The ECM will re speed. The engine will remain at idle or safe speed while the diagnostic codes remain active.

Possible Performance Effect:

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

CID 0091 FMI 0

the diagnostic code. The diagnostic

turn the engine to idle or a safe

i01798141

2Throttle Demand Sensor Erratic Or Intermittent

Possible Performance Effect:

Low power

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

i01798140

CID 0041 FMI 04 8v Senso r Power Supply, Voltag e Less Than Normal

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

Conditions W

Iftheengineisequippedwithathrottleswitchthen the signal f

Iftheengineisequippedwithathrottleposition sensor then switch is invalid.

System Resp

The ECM will log the diagnostic code. The diagnostic code may be v

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.

The reduction of speed is determined by the current speed of the engine.

hich Generate This Code:

rom this switch is invalid.

the signal from the throttle idle validation

onse:

iewed on the electronic service tool.

The ECM has been powered for at least three

•

seconds.

RENR2696-01 65

Troubleshooting Section

When a fault is detected and the engine is above the predetermined speed to the safe speed.

When a fault is predetermined safe speed, the engine will match the correct speed.

The throttle switch is ignored by the ECM until the fault is repaired.

ThethrottleswitchwillalsobeignoredbytheECM until the keyswitch has been turned to the OFF position and

Troubleshooting:

Proceed to “Test Step 1” if the engine is equipped with a t hrottle switch.

Proceed to “Test Step 2” if the engine is equipped with a throttle position sensor.

safe speed, the engine will reduce

detected and the engine is below the

then back to the ON position.

Test Step 1.

Perform the Switch Circuit - Test”

Results:

following diagnostic procedure: “Throttle

System Response:

The ECM will log the diagnostic code. The diagnostic codes may be viewed on the electronic service tool.

TheECMwillreturntheenginetolowidleortothe predetermined safe speed while the diagnostic code remains activ

Possible Performance Effect:

Low power

•

Reduced engin

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Switch Circuit - Test”

Results:

OK – STOP.

•

CID 0091 FMI 0

e speed

i01798143

4Throttle Demand Sensor Shorted Low

OK – STOP.

•

Test Step 2.

Perform the Position Circuit - Test”

Results:

OK – STOP.

•

following diagnostic procedure: “Throttle

i01798142

CID 0091 FMI 03 T hro ttle Demand Sens

or Open Circuit

Or Shorted High

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

The ECM has

•

The ECM reads a signal voltage that is above

•

normal.

been powered for at least 3 seconds.

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

The ECM has be

•

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.

TheECMwillreturntheenginetothelowidleorto the predetermined safe speed while the diagnostic code remain

Possible Performance Effect:

Low power

•

Reduced eng

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

en powered for at least 3 seconds.

sactive.

ine speed

66 RENR2696-01 Troubleshooting Section

Results:

OK – STOP.

•

i01798144

CID 0091 FMI 08 T hro ttle Demand Sensor Abnormal Signal

Conditions Which Generate This Code:

The ECM is not r signal.

System Respon

The ECM will log the diagnostic code. The diagnostic code may be vi

The ECM returns the engine to low idle or a safe speed when th code is logged only if the engine is running. The electronic service tool will indicate DIAG and a throttle position of active. This will happen regardless of the position of the throttle pedal assembly. The engine will remain at low idle or a

Troubleshooting:

The diagnostic code is likely to be caused by one of the following conditions:

eceiving a correct throttle position

se:

ewed on the electronic service tool.

e problem is detected. The diagnostic

0 percent while the diagnostic code is

t the safe speed while the code is active.

A 5 volt failure

•

A5voltfault

•

System Respons

The ECM will log the diagnostic code. The diagnostic code may be vie

TheECMwillreturntheenginetothelowidleorto the pred eterm code remains active.

Possible Perf

Low power

•

Reduced engine speed

•

Troubleshoot

Perform the following diagnostic procedure: “Throttle Position Sen

Results:

OK – STOP.

•

wed on the electronic service tool.

ined safe speed while the diagnostic

ormance Effect:

ing:

sor Circuit - Test”

i01798146

CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit Or Shorted Hi

Open circuit for the throttle position sensor

•

Open circu

•

Perform the following diagnostic procedure: “Throttle Position S

Results:

OK – STOP.

•

it for the voltage supply

ensor Circuit - Test”

i01798145

CID 0091 FMI 12 T hro ttle Demand Sensor Out Of Calibrati

Conditions Which Generate This Code:

The ECM det

ects the following conditions:

Conditions Which Generate This Code:

The ECM dete

Signal voltage is above normal.

•

The ECM has been powered for at least 15

•

seconds.

CID 262-03 5V Sensor Power Supply, Voltage

•

More Than Normal and CID 262-04 5V Sensor Power Suppl active.

System Resp

The ECM will set the engine oil pressure to a default value.

The electronic service tool will display “Open/Short High” for t

cts all of the following conditions:

y, Voltage Less Than Normal are not

onse:

he engine oil pressure on the status screen.

RENR2696-01 67

Troubleshooting Section

The ECM will generate a CID 100 FMI 03 diagnostic code on the Data displayed on the diagnostic screen of the electronic service tool.

Troubleshooting:

Perform the fo

Perform the following diagnostic procedure: “Engine Pressure Sens

Results:

OK – STOP.

•

Link. The diagnostic code will be

llowing diagnostic procedure:

or Open or Short Circuit - Test”

i01798147

CID 0100 FMI 04 Engine Oil Pressure Sen sor Shorted Low

Conditions W

The ECM detects all of the following conditions:

hich Generate This Code:

i01877641

CID 0100 FMI 10 Engine Oil Pressure Sen sor, Power Supply Open Ci

Conditions Which Generate This Code:

If the 5 volt co circuit, this fault will result in a logged code.

The Electroni the following conditions:

No other CID 02

•

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 to

nnection to the sensor is an open

c Control Module (ECM) detects all of

62 or CID 0102 codes are active.

osmall.

rcuit

The signal voltage that is below normal

•

The ECM has be

•

seconds.

CID 262-03 5V

•

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 t he electronic service tool. The ECM flag default value is used.

Troublesho

Perform the following diagnostic procedure:

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

oting:

en powered for at least two

Sensor Power Supply, Voltage

s oil pressure as invalid data and a

All of the above conditions occur simultaneously

•

for a period o

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool. The ECM will data. The engine oil pressure is set to a default value.

Possible Pe

Perform the following diagnostic procedure: “Engine Pressure Se

Results:

OK – STOP.

•

f 10 seconds.

flag the engine oil pressure as invalid

rformance Effect:

nsor Open or Short Circuit - Test”

i01798148

CID 0102 FM I 03 Intake Manifold Pressure Sensor, Open Circu

it Or Shorted H igh

Conditions Which Generate This Code:

The Electr the following conditions:

The ECM rea

•

normal.

onic Control Module (ECM) detects all of

ds a signal voltage that is above

68 RENR2696-01 Troubleshooting Section

The ECM has been powered for at least fifteen

•

seconds.

CID 262-03 5V Sensor Power Supply Voltage More

•

Than Normal an Supply Voltage Less Than Normal are not active.

System Respon

The ECM will set the intake manifold pressure to a default value

The electronic service tool will display “Open/Short High” for the screen.

The ECM will g code on the Data Link. The diagnostic code will be displayed on a diagnostic screen of the electronic service tool

Possible Performance Effect:

Theenginecouldhavelowpowerwhilethediagnostic code is active.

Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

d CID 262-04 5V Sensor Power

se:

intake manifold pressure on the status

enerate a CID 102 FMI 03 diagnostic

System Response:

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 Dat displayed on a diagnostic screen of the electronic service tool.

Possible Performance Effect:

The engine co code is active.

Perform the f Pressure Sensor Open or Short Circuit - Test”

Results:

OK – STOP.

•

aLink.Thediagnosticcodewillbe

uld have low power while the diagnostic

ollowing diagnostic procedure: “Engine

i01877642

CID 0102 FM I 10 Intake Manifold Pr

essure Sensor

Power S upply Op en Circuit

i01798149

CID 010 2 FMI

04 Intake Manifold Pressure Sensor Shorted Low

Condition

The Electronic Control Module (ECM) detects all of the follow

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 Power Supply, Voltage Less Than Normal are not active.

s Which Generate This Code:

ing conditions:

Normal and CID 262-04 5V Sensor

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 s

•

The pressure sensor signal from the intake

•

manifold i mode.

The pressu

•

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.

peed is greater than 600 rpm.

s within the expected range for this failure

re sensor signal from the intake

RENR2696-01 69

Troubleshooting Section

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on t he electronic service tool. The ECM will fl 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.

•

CID 010 5 FMI 0

ag the intake manifold pressure as

i01798150

3 Intake Manifold Temperature Sensor Open Circuit Or Sh orted High

Conditions W

The Electronic Control Module (ECM) detects all of the followi

The ECM reads signal voltage that is above

•

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 t he electronic service tool. The ECM fla data and a default value is used.

Possible P

Low power

•

Poor cold starting

•

hich Generate This Code:

ng conditions:

gs the intake air temperature as invalid

erformance Effect:

i01798151

CID 0105 FM I 04 Intake Manifold Temperature Sensor Shorted Low

Conditions Which Generate This Code:

The Electroni the following conditions:

The ECM reads s

•

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 data and a default value is used.

Possible Per

Low power

•

Poor cold starting

•

Troubleshoo

Perform the following diagnostic procedure: “Engine Temperature

Results:

OK – STOP.

•

c Control Module (ECM) detects all of

ignal voltage that is below normal.

the intake air temperature as invalid

formance Effect:

ting:

Sensor Open or Short Circuit - Test”

i01798152

CID 0110 FMI 03 Engin e Coolant Temperatu re Sensor Open Circui

tOrShortedHigh

Troublesh

Perform the following diagnostic procedure: “Engine Temperatu

Results:

OK – STOP.

•

ooting:

re Sensor Open or Short Circuit - Test”

Conditions Which Generate This Code:

The Electr the following conditions:

The ECM rea

•

normal.

The ECM has

•

seconds.

onic Control Module (ECM) detects all of

ds signal voltage that is above

been powered for at least three

70 RENR2696-01 Troubleshooting Section

System Response:

The ECM will log the diagnostic code. The diagnostic code may be viewed on t he electronic service tool. The ECM flags c and a default value is used.

Possible Perf

Engine misfires

•

Low power

•

Reduced engin

•

Poor cold starting

•

Troubleshooting:

Further troub

Perform the following diagnostic procedure: “Engine Temperature

Results:

OK – STOP.

•

oolant temperature as invalid data

ormance Effect:

e speed (rpm)

leshooting is required.

Sensor Open/Short Circuit - Test”

i01798153

Reduced engine speed (rpm)

•

Poor cold starting

•

Troubleshooti

Further troubleshooting is required.

Perform the following diagnostic procedure: “Engine Temperature Sensor Open/Short Circuit - Test”

Results:

OK – STOP.

•

CID 0174 FMI 02

ng:

i01798154

Fuel Temperatu re Sensor Erratic, Intermittent

Conditions W

Note: If both of the following diagnostic codes are

active, then complete failure of the electrical supply:

hich Generate This Code:

the fuel injection pump has suffered a

CID 0110 FMI 04 Engine Coolant Tem perature Sensor Shorted Low

Conditions Which Generate This Code:

The Electro the following conditions:

The ECM read

•

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 t he electronic service tool. The ECM flag and a default value is used.

Possible P

Engine misfires

•

Low power

•

nic Control Module (ECM) detects all of

s signal voltage that is below normal.

s coolant temperature as invalid data

erformance Effect:

174-02

•

342-02

•

Both of the diagnostic codes will be active if there has been a communication fault between the Electronic Control Mod fuel injection pump. When only one of the diagnostic codes is active there is not a fault with the electrical supply for t

If the ECM has detected 174-02 only, then one of the following c

The fuel temperature signal is erratic.

•

Fuel temperature that is intermittent.

•

System Resp

The ECM will log the diagnostic code. The diagnostic code may be The ECM logs the diagnostic code only if the engine is running.

Possible Performance Effect:

The engine

•

The engine will have low power.

•

ule (ECM) and the CAN Data Link for the

he fuel injection pump.

onditions has been detected:

onse:

viewed on the electronic service tool.

may shut down.

RENR2696-01 71

Troubleshooting Section

Troubleshooting:

Further troubleshooting is required.

Perform the fol Injection Pump Circuit - Test”

Results:

OK – STOP.

•

lowing diagnostic procedure: “Fuel

i01798155

CID 0 247 FMI 09 J1939 Datalink, Abnormal Upda

Conditions Which Generate This Code:

The ECM has de with another device on the J1939 data link.

System Respo

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 service tool.

Perform the f “Troubleshooting, “CAN Data Link Circuit - Test”.”

Results:

tected a loss of communications

nse:

a diagnostic screen of the electronic

ollowing diagnostic procedure:

Note: The personality module is a flash personality

module. The per ECM by flash programming.

System Respon

The ECM will not log any diagnostic code except diagnostic co viewed on a display module or on the electronic service tool. As a result of this code, the fuel injection pump is disab start, and the electronic service tool will not be able to reset the diagnostic code in order to allow the enginetosta

Possible Performance Effect:

Engine shutdown

•

Troubleshoo

Check the part number of ECM Personality Module. Ensure that agrees with the original engine arrangement.

Expected Re

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.

sonality module is installed into the

se:

de 0253. The diagnostic code may be

led for the engine. The engine will not

rt.

ting:

the personality module part number

sult:

–STOP.

•

i01798156

CID 0253 FMI 02 Incorrect ECM Software

Conditions Which Generate This Code:

The persona loaded into the ECM in order to determine the power and torque outputs for a particular engine model and/ engine’s personality module is loaded by the factory. A replacement personality module can be loaded into the EC that the personality module is neither the original personality module nor a replacement of the original personal

lity module is the software that is

or a particular engine application. The

M. The diagnostic code 0253 indicates

ity module.

Repair: Reprogram the ECM with the correct personality module. Refer to Troubleshooting, “Flash Pro

STOP.

gramming”.

i01798157

CID 0262 FMI 03 5v Sen sor Power Supp

ly, 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.

72 RENR2696-01 Troubleshooting Section

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

•

Possible engine misfire

•

Troubleshooting:

Further troub

Perform the following diagnostic procedure: “5 Volt Pressure Sens

Results:

OK – STOP.

•

leshooting is required.

or Supply Circuit - Test”

i01798158

CID 0262 FMI 04 5v Senso r Power Supply, Voltag e Less Than Normal

Conditions Which Generate This Code:

The Electron the following conditions:

The ECM read

•

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:

ic Control Module (ECM) detects all of

s signal voltage that is below normal.

Troubleshooting:

Further troubleshooting is required.

Perform the fol Pressure Sensor Circuit - Test”

Results:

OK – STOP.

•

lowing diagnostic procedure: “5 Volt

i01897931

CID 0266 FMI 02 Incorrect Crank-withou

Conditions Which Generate This Code:

The Electron the following conditions:

The C rank Wit

•

closed relay is above 11.5 VDC.

The C rank Wit

•

open relay is below 0.5 VDC.

System Respo

The diagnostic code may be viewed on a display moduleoront

The Crank Without Injection will be disabled.

Possible Performance Effect:

None

•

Troubleshooting:

Perform the following diagnostic procedure: “Crank Without Injection Circuit - Test”

Results:

OK – STOP.

•

ic Control Module (ECM) detects all of

nse:

he electronic service tool.

t-inject inputs

hout Injection input from the normally

Low power

•

Possible engine misfire

•

RENR2696-01 73

Troubleshooting Section

i01798159

CID 0320 FMI 02 Speed And Timing Sensor Intermittent Loss Of Signal

Conditions Which Generate This Code:

The signal for This speed/timing sensor is located near the flywheel housing.

System Response:

The E lectroni speed/timing sensor in the fuel injection pump to determine engine speed. The ECM will log the diagnostic c on the electronic service tool.

Possible Pe

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/Timi

the speed/timing sensor is intermittent.

c Control Module (ECM) will use the

ode. The diagnostic code may be viewed

rformance Effect:

ng Sensor Circuit - Test”

System Response:

The Electronic Control Module (ECM) will use the speed/timing sensor in the fuel injection pump to determine eng diagnostic code. The diagnostic code may be viewed on the electronic service tool.

Possible Performance Effect:

Theremaybeas

The ECM will limit the maximum engine speed to 1200 rpm.

If the signal is lost from both of the engine speed/timin engine.

Perform the f Speed/Timing Sensor Circuit - Test”

Results:

OK – STOP.

•

REPAIRED, OK – STOP.

•

ine speed. The ECM will log the

light change in engine response.

g sensors, the ECM will shut down the

ollowing diagnostic procedure: “ Engine

i01798161

CID 0342 FMI 02 Speed And Timing Sensor No.2 Intermitte

nt Signal

Results:

OK – STOP.

•

REPAIRED, O

•

CID 0320 FM I

K–STOP.

i01798160

11 Speed And

Timing Senso r Loss O f Signal

Conditions Which Generate This Code:

The signal for the speed/timing sensor is lost. This speed/timing sensor is located near the flywheel housing.

Conditions Which Generate This Code:

Note: If bot

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 comm Control Module (ECM) and the CAN data link for the fuel injection pump. If only the 0342-02 is active there is not a fau injection pump.

The signa injection pump is intermittent or lost for less than one second.

h of the following diagnostic codes are

unication fault between the Electronic

lt with the electrical supply for the fuel

l for the speed/timing sensor in the fuel

74 RENR2696-01 Troubleshooting Section

System Response:

The Electronic Control Module (ECM) will log the diagnostic code. The ECM will force the engine to a default value may be viewed on the electronic service tool.

Possible Perf

The engine will shut down.

or a safe speed. The diagnostic code

ormance Effect:

Test Step 1.

Perform the fo Injection Pump Circuit - Test”

Results:

OK – STOP.

•

llowing diagnostic procedure: “Fuel

Test Step 2.

Perform the f Data Link Circuit - Test”

Results:

OK – STOP.

•

REPAIRED, OK – STOP.

•

ollowing diagnostic procedure: “CAN

i01798162

CID 0774 FMI 02 T hro ttle Demand Sensor No.2 Erratic Or Intermit

tent

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.

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 s

When a fault is detected and the engine is below the predetermin correct speed.

The throttle repaired.

The throttle until the keyswitch has been turned to the OFF position and then back to the ON position.

Low power

•

Reduced eng

•

Perform the following diagnostic procedure: “Throttle Switch Circ

Results:

OK – STOP.

•

afe speed.

ed safe speed, the engine will match the

is ignored by the ECM until the fault is

switch will also be ignored by the ECM

ine speed

uit - Test”

i01798163

Conditions Which Generate This Code:

The ECM dete

Erratic data

•

Intermittent data

•

Incorrect d

•

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.

cts one of the following conditions:

ata

CID 0774 FMI 03 Throttle Demand Sensor No.2 O pe n Circuit O r

Conditions Which Generate This Code:

The ECM det

Voltage for the throttle position sensor is above

•

normal.

Invalid throttle position signal

•

System Response:

The ECM wil code may be viewed on the electronic service tool.

Shorted High

ects one of the following conditions:

l log the diagnostic code. The diagnostic

RENR2696-01 75

Troubleshooting Section

The ECM will return the engine to low idle or to a safe speed while the

Possible Performance Effect:

Low power

•

Reduced engin

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

Results:

OK – STOP.

•

CID 0774 FMI 04

diagnostic code is active.

e speed

i01798164

Throttle Demand Sensor No.2 Shorted Low

i01798165

CID 0774 FMI 08 Throttle Demand Sensor No.2 Abnormal Sign

Conditions Which Generate This Code:

The ECM detect

Voltage for the throttle position sensor is abnormal.

•

Invalid throttle position signal

•

System Respon

The ECM will log the diagnostic code. The diagnostic code may be vie

TheECMwillreturntheenginetolowidleortoasafe speed while t

Possible Performance Effect:

s one of the following conditions:

se:

wed on the electronic service tool.

he diagnostic code is active.

Conditions W

The ECM detects one of the following conditions:

Voltage for the throttle position sensor is below

•

normal.

Invalid throttle position signal

•

System Respo

The ECM will log the diagnostic code. The diagnostic code may be v

The ECM will return the engine to low idle or to a safe speed while

Possible Performance Effect:

Low power

•

Reduced eng

•

Troubleshooting:

Perform the following diagnostic procedure: “Throttle Position Sensor Circuit - Test”

hich Generate This Code:

nse:

iewed on the electronic service tool.

the diagnostic code is active.

ine speed

Low power

•

Reduced engi

•

Perform the following diagnostic procedure: “Throttle Position Sen

Results:

OK – STOP.

•

ne speed

sor Circuit - Test”

i01798166

CID 0774 FMI 12 Throttle Demand Sensor No.2 Out O f Calibratio

Conditions Which Generate This Code:

The ECM dete

Throttle position sensor signal is abnormal.

•

Failure of the throttle position sensor

•

cts one of the following conditions:

Results:

OK – STOP.

•

System Resp

The ECM will log the diagnostic code. The diagnostic code may be v

TheECMwillreturntheenginetolowidleortoasafe speed while

onse:

iewed on the electronic service tool.

the diagnostic code is active.

76 RENR2696-01 Troubleshooting Section

Possible Performance Effect:

Low power

•

Reduced engine

•

Perform the following diagnostic procedure: “Throttle Position Sens

Results:

OK – STOP.

•

speed

or Circuit - Test”

i01877645

CID 1627 FMI 03 F ue l Injection Pump R e lay Did No t Turn Off

Conditions W

The ECM still receives signals from the relay of the fuel injecti switched off the relay.

hich Generate This Code:

on pump even though the ECM has already

The fuel temperature may be above the recommended ma The Perkins recommended maximum operating fuel temperature is 70 °C (158.0 °F) at the inlet to the fuel injection pum note that the fuel temperature is too high.

There may be a pump.

System Respo

The ECM will log the diagnostic code. The diagnostic code may be vi

The fuel injection pump will reduce the available quantity of f too high and the diagnostic code is still active. E054 High Fuel Temperature Derate is the event code that will be logg

Possible Performance Effect:

The fuel injection pump will be derated.

•

Low engine p

•

ed on the ECM.

ximum operating temperature.

p. The electronic fuel injection pump will

n internal fault within the fuel injection

nse:

ewed on the electronic service tool.

uel for injection if the fuel temperature is

ower

System Respo

The ECM will log the diagnostic code. The diagnostic code may be vi

Possible Performance Effect:

Perform the following diagnostic procedure: “Fuel Injection Pump Circuit - Test”

Results:

OK – STOP.

•

CID 1684 FMI 0

nse:

ewed on the electronic service tool.

i01798167

0 Fuel Injection Pump, Fuel Tem perature More Than Normal

Conditions

This code is generated by the fuel injection pump.

Which Generate This Code:

Reduced engine speed

•

Test Step 1.

Check the fu

Check the fuel temperature.

Check for active diagnostic codes

Results:

OK – STOP.

•

el system for restrictions.

Test Step 2.

If the fault Operation, Testing and Adjusting, “Fuel System Inspect”.

Results:

OK – STOP.

•

has not been eliminated refer to Systems

There are two conditions that will generate this code:

RENR2696-01 77

Troubleshooting Section

i01798168

CID 1684 FMI 02 F ue l Injection Pump, Software F ailure

Conditions Wh

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 lo code may be viewed on the electronic service tool.

The ECM will n diagnostic code is active.

If the engine becomes active, the ECM will cause the engine to shutdown.

Possible Performance Effect:

The ECM will c

The engine will not start while the diagnostic code is active.

ich Generate This Code:

g the diagnostic code. The diagnostic

ot allow the engine to start while the

is running and the diagnostic code

ausetheenginetoshutdown.

i01798169

CID 1684 FMI 03 Fu el Injection Pump, Fuelling Fault

Conditions Wh

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 lo code may be viewed on the electronic service tool.

System Respon

The ECM will have no response to this active code. Theenginema

Possible Performance Effect:

An incorrect amount of fuel may be injected into the cylinders. Continuing to use the engine under these conditions m

Troubleshooting:

Contact the Perkins Technical Support Centre in order to check if the software version is correct. Also check that th

ich Generate This Code:

g the diagnostic code. The diagnostic

se:

y have reduced power.

ay lead to engine failure.

ere have been no software updates.

Troubleshooting:

Contact the Perkins T echnical Support Centre in order to check if the software version is correct. Also check that t

If the problem still exists contact the Perkins Technical Support Cen pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultat

Replace the fuel injection pump. Refer to Disassembly and Assemb Install”.

Check for a

Results:

OK – STOP.

•

here have been no software updates.

tre in order to change the fuel injection

ion.

ly, “Fuel Injection Pump Remove and

ctive diagnostic codes.

If the problem still exists contact the Perkins Technical Support Cen pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prior consultati

Replace the fuel injection pump. Refer to Disassembly and Assembl Install”.

Check for a

Results:

OK – STOP.

•

tre in order to change the fuel injection

on.

y, “Fuel Injection Pump Remove and

ctive diagnostic codes.

i01798170

CID 1684 FMI 04 Fu el Injection Pump, Supply Voltage Fault

Condition

This code is generated by the fuel injection pump.

s Which Generate This Code:

78 RENR2696-01 Troubleshooting Section

The fuel injection pump detects one of the following conditions whi

Supply voltage below normal

•

Intermittent signal

•

The ECM will lo code may be viewed on the electronic service tool.

System Respon

Possible Performance Effect:

The diagnostic code is logged, but there will be no other system response.

There is no obvious effect on engine performance.

•

Troubleshoot

Further troubleshooting is required.

Perform the following diagnostic procedure: “Fuel Injection Pump Circuit - Test”

Results:

le the engine is running:

g the diagnostic code. The diagnostic

se:

ing:

Troubleshooting:

A. Connect a test ECM in order to determine if

the problem is in the original ECM or in the fuel injection pum

Note: The parameters of the test ECM must match the parameter resolves the problem, reconnect the suspect ECM. Verify that the problem returns. If the problem returns, replace the s

B. If the ECM is OK, contact the Perkins Technical

Support Cent injection pump. The warranty of the fuel injection pump will be affected if the pump is replaced without prio

Replace the fuel injection pump. Refer to Disassembl Remove and Install”.

C. Check for ac

Results:

OK – STOP.

•

s in the suspect ECM. If the test ECM

uspect ECM.

re in order to change the fuel

r consultation.

y and Assembly, “Fuel Injection Pump

tive diagnostic codes.

OK – STOP.

•

i01798171

CID 1684 FMI 0

5 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 p

The ECM will log the diagnostic code. The diagnostic code may be v

TheECMwillcausethefuelinjectionpumptostop injecting f shut down while the diagnostic code is active.

ump.

iewed on the electronic service tool.

uel. The ECM will then cause the engine to

i01798172

CID 1684 FMI 07 Fu el Injection Pump, Mechanical Fault

Condition

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 wil injecting fuel. The ECM will then cause the engine to shut down while the diagnostic code is active.

Possible Performance Effect:

The engine

Troubleshooting:

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

s Which Generate This Code:

lcausethefuelinjectionpumptostop

will shut down.

Check for active diagnostic codes.

RENR2696-01 79

Troubleshooting Section

Results:

OK – STOP.

•

i01798173

CID 1684 FMI 08 F ue l Injection Pump, Crankshaft Reference Fault

Conditions Which Generate This Code:

This code is ge

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 incor

The ECM will log the diagnostic code. The diagnostic code may be vi

System Response:

The fuel injection pump will use the engine speed/timing sensor in order to set the engine timing. The ECM will the diagnostic code is active.

nerated by the fuel injection pump.

rect.

ewed on the electronic service tool.

derate the engine power by 20% while

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 atte

P1/J1 ECM connector

•

P40/J40 Fuel injection pump connector

•

P1:59 Engine p

•

P40:8 Engine position

•

Refer to Troubleshooting, “Electrical Connectors Inspect”.

Results:

OK – Proceed to

•

ntion to the following areas:

osition

Test Step 4.

Check continuity between the following connections:

P1:59 Engine p

•

osition

Possible Pe

The engine will experience any of the following conditions

Small loss of engine performance

•

Increased emissions

•

Theenginem

•

Troubleshooting:

Further troubleshooting is required.

rformance Effect:

ay be difficult to start.

Test Step 1.

Check for the following active code:

Diagnostic code 320-02

•

Diagnostic

•

Results:

Codes Active – Proceed to Test Step 2.

•

code 320-11

P40:8 Engine position

•

Expected Result:

If the fault i

If the fault still exists, repair the wire harness or replace the w

Ensure that the repairs have eliminated the problem.

Check for active diagnostic codes.

Results:

OK – STOP.

•

s cleared then STOP.

ire harness.

80 RENR2696-01 Troubleshooting Section

i01798174

CID 1684 FMI 09 F ue l Injection Pump, CAN Fault

Conditions Wh

This code is generated by the fuel injection pump.

The fuel injection pump detects one of the following conditions:

Failure of the CAN Data Link

•

The ECM sends i

•

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 c the injection of fuel.

Possible Per

TheECMwillcausethefollowingconditions:

The engine will shut down.

•

Theenginewi

•

Troubleshooting:

Further troubleshooting is required.

ich Generate This Code:

ncorrect data.

ause the fuel injection pump to stop

formance Effect:

ll not start.

If the fault is still active, contact the Perkins Technical Support Centre 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 Install”.

Check for act

Results:

OK – STOP.

•

in order to change the fuel injection

, “Fuel Injection Pump Remove and

ive diagnostic codes.

i01798175

CID 1684 FMI 10 Fu el Injection Pump, Fuel Shutoff Signal Error

Conditions Which Generate This Code:

The Electro of the following improper responses from the fuel injection pump.

Open circuit

•

Wire shorte

•

Wire shorted low.

•

The ECM will log the diagnostic code. The diagnostic code may be viewed on the electronic service tool.

nic Control Module (ECM) detects one

dhigh.

Connect a tes original ECM is the cause of the problem.

Note: The par the parameters in the suspect ECM. If the test ECM resolves the problem, reconnect the suspect ECM. Verify that replace the suspect ECM.

Expected Re

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.

t ECM in order to determine if the

ameters of the test ECM must match

the problem returns. If the problem returns,

sult:

System Response:

The engine m is active. Also, the engine may not start while the diagnostic code is active.

Troubleshooting:

Further tr

ay shut down while the diagnostic code

oubleshooting is required.

Test Step 1.

Use a multimeter to check the following connections:

J1:1

•

P40:5

•

RENR2696-01 81

Troubleshooting Section

Note: While the engine is cranking and running, the battery voltag volts.

Ensure that th

Results:

Check for active diagnostic codes – STOP.

•

e at terminal P40:5 should drop to 0

e problem has been eliminated.

Test Step 2.

Connect a test ECM to the engine in order to determine if t

Note: The parameters of the test ECM must match the parameter resolves the problem, reconnect the suspect ECM. Verify that the problem returns. If the problem returns, replace the s

Results:

OK – STOP.

•

Not OK – Proce

•

he original ECM is causing the problem.

s in the suspect ECM. If the test ECM

uspect ECM.

ed to Test Step 3.

The ECM will log the diagnostic code. The diagnostic code may be view

System Response:

The ECM will derate the engine power by 20% while the diagnostic code is active.

Possible Performance Effect:

The engine may conditions while the diagnostic code remains active:

Low power

•

Reduced engine speed

•

Troubleshooting:

Further troub

ed on the electronic service tool.

experience any of the following

leshooting is required.

Test Step 1.

Check the tightness of all fuel line connections. Check for air in the fuel injection pump. Refer to Operation and Maintena

nce Manual, “Fuel System - Prime”.

Test Step 3.

Contact the Perkins T echnical Support Centre in order to change the fuel injection pump. The warranty of the fuel i is replaced without prior consultation.

Replace the and Assembly, “Fuel Injection Pump Remove and Install”.

Check for active diagnostic codes.

Results:

OK – STOP.

•

njection pump will be affected if the pump

fuel injection pump. Refer to Disassembly

i01798176

CID 1684 FMI 11 F uel Injection Pump, Inte

Conditions Which Generate This Code:

rnal Sensor Fault

Results:

OK – Proceed to Test Step 2.

•

Test Step 2.

Refer to Troubleshooting, “Fuel Injection Pump Circuit - Tes

Check for active diagnostic codes.

Results:

OK – STOP.

•

CID 1684 FMI 1

t”.

i01798177

2 Fu el Injection

Pump, Device Failure

Conditions Which Generate This Code:

This code is generated by the fuel injection pump.

This code i

The problem is internal to the fuel injection pump.

There may be air in the fuel injection pump.

The voltag the fuel injection pump are incorrect.

s generated by the fuel injection pump.

e and/or resistance at the connectors for

The problem

The ECM will log the diagnostic code. The diagnostic code may be v

is internal to the fuel injection pump.

iewed on the electronic service tool.

82 RENR2696-01 Troubleshooting Section

System Response:

The ECM will derate the engine power by 20% while the diagnostic code is active.

Possible Performance Effect:

While the diag experience the following conditions:

Low power

•

Reduced engine speed

•

Troubleshooting:

Contact the Pe 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 war 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.

•

nostic code is active the engine will

rkins Technical Support Centre in

ranty of the fuel injection pump will

Possible Performance Effect:

The 1684-14 diagnostic code will not have any effect on the performance of the engine. 1684-14 is normally acco 174-02 may cause the engine to have low power. If 320-02 is active, the ECM will limit the engine rpm to 1200 rpm.

Troubleshooting:

Further troubleshooting is required.

mpanied by 174-02 or 320-02. The

Test Step 1.

Perform the following diagnostic procedure: “CAN Data Link Cir

Results:

OK – STOP.

•

Not OK – Proce

•

cuit - Test”

ed 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.

Note: The parameters of the test ECM must match the paramet resolves the problem, reconnect the suspect ECM. Verify that the problem returns. If the problem returns, replace the

ers in the suspect ECM. If the test ECM

suspect ECM.

i02271066

CID 1684 FMI

14 Fuel Injectio n

Pump, No Communications

Conditions Which Generate This Code:

The ECM detects a communication failure with the fuel injection pump. The communication failure may be due to di injection pump or a faulty wiring harness for the fuel injection pump.

System Response:

The ECM wil code may be viewed on the electronic service tool.

sconnected connectors for the fuel

l log the diagnostic code. The diagnostic

Check for active diagnostic codes.

Results:

OK – STOP.

•

Not OK, 1684-14 is still active. – Proceed to T est

•

Step 3.

Test Step 3.

Contact the Perkins Technical Support Centre in order to check if the software version is correct. Also check that

If the problem still exists, the fuel injection pump must be rep Support Centre in order to replace the fuel injection pump. The warranty of the fuel injection pump will be affect consultation. Refer to Disassembly and Assembly, “Fuel Injection Pump Remove and Install”.

Check for active diagnostic codes.

there have been no software updates.

laced. Contact the Perkins Technical

ed if the pump is replaced without prior

RENR2696-01 83

Troubleshooting Section

Results:

OK – STOP.

•

i01798179

CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invalid State

Conditions Which Generate This Code:

The ECM has det conditions:

Erratic data

•

Intermittent data

•

Incorrect data

•

System Respo

The ECM will return the engine to the last good mode selecti engine to advance to another mode selection until the problem is repaired.

ected one of the following

nse:

on or setting. The ECM will not allow the

Incorrect data

•

System Response:

The engine spee speed.

The ECM will lo code may be viewed on the electronic service tool.

The ECM will ha There is no loss of engine performance.

Troubleshoot

Further troubleshooting is required.

Refer to Troubleshooting, “Throttle Switch Circuit Tes t ”.

Results:

OK – STOP.

•

CID 1895 FMI 0

d fails to disengage from the set

g the diagnostic code. The diagnostic

ve no response to this active code.

ing:

i01798181

2SetSpeed Control Speed Toggle Switch, Invalid State

Possible Performance Effect:

Theenginewi engine speed.

Troublesho

Refer to Troubleshooting, “Mode Selection Circuit Tes t ”.

Results:

OK – STOP.

•

ll start but the engine will have reduced

oting:

i01798180

CID 1894 FMI 02 Set Speed Control Disengage Switch State, Inv

Conditions Which Generate This Code:

The ECM det

Erratic data

•

Intermittent data

•

alid State

ects one of the following conditions:

Conditions W

The ECM detects one of the following conditions:

Erratic data

•

Intermitte

•

Incorrect data

•

System Response:

The engine sp speed.

The ECM will code may be viewed on the electronic service tool.

The ECM will There is no loss of engine performance.

Troublesho

Further troubleshooting is required.

Refer to Troubleshooting, “Throttle Switch Circuit Tes t ”.

hich Generate This Code:

nt data

eed fails to disengage from the set

log the diagnostic code. The diagnostic

have no response to this active code.

oting:

84 RENR2696-01 Troubleshooting Section

Results:

OK – STOP.

•

RENR2696-01 85

Troubleshooting Section

Troubleshooti

ng with an

Event Code

i01798182

Event Codes

Note: If a diagnostic code has already been logged

then any assoc be logged as well.

TheECMcanlo operating conditions such as low oil pressure or high coolant temperature. Logged events usually indicate a mechanical system problem.

Programmable Engine Parameters

The followi

Engine Warning

•

iated event code to that fault will not

g events. Events refer to engine

problem instead of an electronic

ng features may be programmed:

Results:

OK – STOP.

•

i01897925

E016 H igh Engine Coolant Temperatu re Shutdow n

Conditions Wh

The engine has been running for at least 3 minutes. The engine coo trip point and the delay time has expired.

System Respon

Iftheengineshutdownis“ENABLED”thefuelwillbe shut off. The

Possible Performance Effect:

The engine is shut down.

ich Generate This Code:

lant temperature has exceeded the

se:

event will be logged.

Engine Derate

•

Engine Shut

•

When the features are activated the event will be logged in th

down

eECM.

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:

Troubleshoo

Refer to Troubleshooting, “Coolant Temperature Is Too H ig h ”.

Results:

OK – STOP.

•

ting:

i01798184

E017 H igh Engine Coolant Temperature Warning

Conditions

The engine has been running for at least 3 minutes. The engine c trip point and the delay time has expired.

System Resp

The alarm output is activated. The event is logged.

Which Generate This Code:

oolant temperature has exceeded the

onse:

The engine power is reduced.

Troubleshooting:

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

Possible Performance Effect:

The engine o However, if the coolant temperature continues to rise, the engine will be derated.

peration is not immediately affected.

86 RENR2696-01 Troubleshooting Section

Troubleshooting:

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

Results:

OK – STOP.

•

i01798185

E025 High Inta

ke 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 the intake manifold air temperature are active.

System Respo

The alarm output is activated. The event is logged.

Possible Performance Effect:

The engine po

Troubleshooting:

Refer to Troubleshooting, “Intake Manifold Air Temperature Is Too High”.

time has expired. No other codes for

nse:

wer is reduced.

The intake manifold air temperature is greater than

•

76 °C (168 °F) fo

The intake manifold air temperature is greater than

•

135 °C (275 °F)

The intake manifold air temperature is greater

•

than 82 °C (179 turbocharged engine.

Theintakeman

•

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

•

74 °C (165 °F) for the 1106 engine.

The intake manifold air temperature is less than

•

133 °C (271 °F) for the 1104 turbocharged engine.

The intake manifold air temperature is less

•

than 80 °C (176 °F) for the aftercooled 1104 turbocharg

The intake manifold air temperature is less than

•

110°C(230° engine.

System Resp

The alarm output is activated. The code is logged.

Possible Performance Effect:

r the 1106 engine.

for the 1104 turbocharged engine.

°F) for the aftercooled 1104

ifold air temperature is greater than

ed engine.

F) for the 1104 naturally aspirated

onse:

Results:

OK – STOP.

•

i01798186

E027 High Int

ake 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 thetrippoi delay time of 4 seconds has expired. No other codes for the intake manifold air temperature are active. Th air temperature cools below the trip point for the machine application.

The ECM detects the following conditions:

nt for the machine’s application and the

e ECM will reset when the intake manifold

The ECM wil continue to derate the engine at a higher rate as the intake manifold air temperature rises.

Troubleshooting:

Refer to Tr Temperature Is Too High”.

Results:

OK – STOP.

•

l derate the engine. The ECM will

oubleshooting, “Intake Manifold Air

i01983787

E040 Low Engine Oil Pressure Shutdown

Conditions Which Generate This Code:

The ECM det

ects the following conditions:

RENR2696-01 87

Troubleshooting Section

The engine has been running for at least 5

•

seconds.

The engine speed is above 350 RPM.

•

The engine oil pressure is less than 100 kPa

•

(14.5 psi).

The two second delay time has expired.

•

No codes for th

•

active.

System Respon

The code is logged. The ECM will reset the shutdown when the oil pr low pressure trip line for 20 seconds. If the engine shutdown input is “ENABLED” and there is no rise in oil pressure off after the two second delay has expired.

Possible Per

Theengineisshutdown.

Troubleshooting:

e engine oil pressure sensor are

se:

essure rises 21 kPa (3 psi) above the

above the trip line, the fuel will be shut

formance Effect:

Troubleshooting:

Theremaybeaproblemwiththefuelsystem.

•

There may be a pr

•

sensor.

Test Step 1. Ch

A. Connect the electronic service tool to the service

tool connecto

B. Turn the keyswitch to the ON position. The engine

should be off.

C. Check for any active diagnostic codes or logged

diagnostic co

Expected Result:

There should be no diagnostic codes that are present.

Results:

OK – Proceed to Test Step 2.

•

Not OK

•

oblem with the fuel temperature

eck for Diagnostic Codes.

des.

Refer to Trou

Results:

OK – STOP.

•

bleshooting, “Low Engine Oil Pressure”.

i01798188

E054 High Fuel Temperature Derate

Conditions

The engine has been running for at least 3 seconds and the fuel the machine’s application.

System Resp

The warning lamp will flash while the “Derate” is active.

The electronic service tool will display “Engine Derate” in service tool status screen.

The ECM wil theDataLink.Theeventcodewillbedisplayedona diagnostic screen of the electronic service tool.

Which Generate This Code:

temperature is above the trip point for

onse:

the first engine status box on any electronic

l generate a EID E054 event code on

Repair: Repa present. Refer to the appropriate topic in the “Troubleshooting With a Diagnostic Code” section of this manua

Ensure that the repair eliminates the problem.

STOP.

Test Step 2. P

ir the diagnostic codes that are

erform a Check of the Fuel

System.

A. Perform a check of the fuel system. Refer to the

appropriat possible causes.

Expected Re

There are no problems with the fuel system.

Results:

OK – There m

•

Repair: Monitor the operation of the engine.

Repair the problem.

Ensure that

STOP.

Not OK

•

e topic in Testing and Adjusting for

sult:

ay be an intermittent problem.

the repair eliminates the problem.

Repair: Rep

air the problem.

88 RENR2696-01 Troubleshooting Section

Ensure that the repair eliminates the problem.

STOP.

i01798189

E056 High Fuel Temperature Warning

Conditions Wh

The fuel temperature has exceeded the trip point and the delay t the warning when the fuel temperature is above the reset value.

The ECM detects all of the following conditions:

The engine ha

•

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

•

intermitte

System Response:

The ECM will log the event. The event code can be viewed on the diagnostic screen of the electronic service too

Troubleshooting:

There may be a problem with the fuel system.

•

There may be

•

sensor.

ich Generate This Code:

ime has expired. The ECM will reset

s been running at least three

a problem with the fuel temperature

Not OK

•

Repair: Repair the diagnostic codes that are present. Refer to the appropriate topic in the “Troubleshoo of this manual.

Ensure that th

STOP.

ting With a Diagnostic Code” section

e repair eliminates the problem.

Test Step 2. Perform a Check of the Fuel System.

A. Perform a che

appropriate topic in Testing and Adjusting for possible causes.

Expected Result:

There are no p

Results:

OK – There may be an intermittent problem.

•

Repair: Moni

Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

Not OK

•

Repair: Repair the problem.

Ensure that

STOP.

ck of the fuel system. Refer to the

roblems with the fuel system.

tor the operation of the engine.

the repair eliminates the problem.

Test Step 1.

A. Connect the electronic service tool to the service

tool connec

B. Turn the keyswitch to the ON position. The engine

should be o

C. Check for any active diagnostic codes or logged

diagnosti

Expected Result:

There should be no diagnostic codes that are present.

Results:

OK – Proceed to Test Step 2.

•

Check for Diagnostic C odes.

tor.

ff.

c codes.

RENR2696-01 89

Troubleshooting Section

i01983749

E100 L ow Engine Oil Pressu re Warning

Conditions Wh

Illustration 17

Oil pressure map for the 1104E engine

ich Generate This Code:

g01028820

System Response:

The ECM will log the event. The ECM will reset the warning when the oil pressure rises 21 kPa (3 psi) above the thre

Possible Performance Effect:

None

•

Troubleshoot

There may be a problem with the engine lubrication

•

system.

Theremaybeaproblemwiththeengineoil

•

pressure sens

shold for at least four seconds.

ing:

or.

Test Step 1. Check for Active Diagnostic Codes.

A. Start the electronic service tool.

B. Turn the main

C. Check for any Active Diagnostic Codes or Logged

Diagnostic C

power to the ON position.

odes.

Illustration 18

Oil pressure map for the 1106E engine

The Electronic Control Module (ECM) detects the following conditions:

The engine has been running for at least 5

•

seconds.

The engine speed is at least 350 rpm.

•

Engine oil pressure is lower than the threshold for

•

low oil pressure for more than 2 seconds.

100-03 “Engine Oil Pressure open/short to +batt” is

•

not active.

g01028718

Expected Result:

There should be no diagnostic codes that are present.

Results:

OK –Therearenodiagnosticcodesthatare

•

present. Pr

Not OK – There are diagnostic codes that are

•

present.

Repair: Repair the diagnostic codes that are present. Re “Troubleshooting With a Diagnostic Code” section of this manual. Ensure that the repair eliminates the proble

STOP.

oceed to test step 2.

fer to the appropriate topic in the

Test Step 2. Perform a Check of the Engine Lubrication System.

A. Perform a c

system. Refer to the diagnostic procedure Troubleshooting, “Low Engine Oil Pressure”.

Expected Result:

heck of the engine lubrication

100-04 “Engine Oil Pressure short to ground” is

•

not active.

100-10 Engine Oil Pressure Sensor abnormal rate

•

of change is not active.

There sho pressure.

uld be no problems with engine oil

90 RENR2696-01 Troubleshooting Section

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.

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

Expected Result:

Results:

OK – STOP.

•

i01798192

E442 Engine Fa

iledtoStop

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:

Conditions W

Engine speed is above 3000 rpm for the 1104 for more than 0.6 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 rep

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

Troublesh

This event indicates excessive engine speed. This does not re Module (ECM). This does not represent a problem with the Electronic Speed/Timing Sensor.

hich Generate This Code:

seconds or the engine speed is above

resent an electronic system fault.

ooting:

present a problem with the Engine Control

If the engine disable the power relay for the fuel injection pump.

The event cod

Possible Performance Effect:

Slow engine shutdown

Troubleshoo

No troubleshooting will be required unless the diagnostic c

still fails to shut down, the ECM will

e is logged in the ECM memory.

ting:

ode 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.

Engine Overspeed Warning

This event No troubleshooting is required.

records the engine overspeed warning.

Results:

OK – STOP.

•

Not OK – Proceed to Test Step 2.

•

RENR2696-01 91

Troubleshooting Section

Test Step 2.

Perform the following diagnostic procedure: “CAN Data Link Circuit - Test”

Results:

OK – STOP.

•

i01798193

E883 Engine Fa

iled To Stop When Fuel Solenoid Disengaged

Conditions Wh

The engine shutdown was slow when the keyswitch was turned to

TheenginefailedtostopwhentheECMdisabled the fuel inje

The engine failed to shutdown when the keyswitch was turned to

ich Generate This Code:

the O FF position.

ction pump.

the O FF position.

Connect a test ECM to the engine in order to determine if th

Note: The parameters of the test ECM must match the parameter

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.

•

e original ECM is causing the problem.

s in the suspect ECM.

Test Step 3.

Replace the fuel injection pump. Refer to Disassembly and Assembly Install”.

Results:

OK – STOP.

•

, “Fuel Injection Pump Remove and

System Response:

The ECM attempts to shut down the engine by instructing the fuel injection pump to stop fuel injection.

The event code is logged in the ECM memory.

Possible Performance Effect:

Slow engine

Troubleshooting:

No troubleshooting will be required unless the diagnostic code 1684-10 is active.

shutdown

Test Step 1.

Use a multim

J1:1

•

P40:5

•

Ensure that

eter to check the following connections:

the problem has been eliminated.

Results:

Check for active diagnostic codes – STOP.

•

Test Step 2.

92 RENR2696-01 Troubleshooting Section

Diagnostic Fun

ctional

Tests

i01798194

5 Volt E ngine P ressure Sensor SupplyCircuit-Test

System Opera

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 di

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 proc

tion Description:

agnostic codes are active:

edure:

The Electronic Control Module (ECM) supplies regulated +

J201/P201 Engine Oil Pressure Sensor

•

J200/P200 Intake Manifold Pressure Sensor

•

J40/P40 Thr

•

The supply for the +5 V engine pressure sensor is routed from 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 harness. The next probable cause is a sensor and the least probable cause is the ECM.

5 VDC to the following sensors:

ottle Sensor

the ECM through ECM engine harness

short circuit or an open circuit in the

RENR2696-01 93

Troubleshooting Section

Illustration 19

The sensor for the intake manifold pressure

Illustration 20

Engine oil pressure sensor

g00884730

g00835146

94 RENR2696-01 Troubleshooting Section

Illustration 21

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

RENR2696-01 95

Troubleshooting Section

ion 22

Illustrat

B. Perform a 45 N (10 lb) pull test on each of the

wires in t with the +5 V sensor supply:

•

Refer to Illustration 22.

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 conn coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.

Results:

OK – Proc

•

Not OK

•

he ECM connector that are associated

P1-14 Int

P1-24 Engine Oil Pressure

P1-26+5V

P1-34 Sen

ake Manifold Pressure

sor Common

ectors, pins and sockets should be completely

eed to Test Step 2.

g00954709

Repair: Repair the connectors or wiring and/or replace t thesealsareproperlyinplaceandensurethatthe connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.

he connectors or wiring. Ensure that all of

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

diagnostic codes.

active

Note: Wait at least 15 seconds in order for the diagno

Expected Result:

Select the condition of the following codes:

•

stic codes to become active.

262-03 tha normal

5 Volt Sensor Power Supply, voltage more

96 RENR2696-01 Troubleshooting Section

262-04 5 Volt Sensor Power Supply, voltage less

•

than normal

Results:

Active – Proceed to Test Step 3.

•

Logged ONLY – P

•

Not Active or Logged – The +5 V supply is

•

operating cor

roceed to Test Step 5.

rectly 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 gi plode.

To avoid inj cause a spark, or smoke in the vicinity of a battery.

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.

ve off flammable fumes which can ex-

ury or death, do not strike a match,

NOTICE

B. Turn the keyswitch to the OFF position while the

engine is off.

RENR2696-01 97

Troubleshooting Section

ion 23

Illustrat

C. Refer to Troubleshooting, “Engine Wiring

Informat

ion” for wiring instructions.

D. Disconnect J1/P1 ECM engine harness connector

E. Connect the J1 bypass harness to the ECM

connect

or.

F. Remove the fuse F1 from the bypass harness and

from the

battery circuit.

G. Connect the unswitched battery cables directly

to the ba

ttery 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 un

til 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.

J. Access the active diagnostic code screen on

the electronic service tool. Check for one of the

ing active diagnostic codes:

262-03 5 Volt Sensor Supply voltage more than

•

normal

g00954711

262-04 5 Volt Sensor Supply voltage less than

•

normal

Note: When ECM engine harness connector J1/P1 is disconne

cted 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 d

iagnostic code is active when the ECM

engine harness connector is disconnected.

Results

•

Yes – The +5 V diagnostic code is active when the ECM engi

ne harness connector is disconnected.

Repair: Temporarily connect a test ECM to the engi

ne 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 Vdiagn

ostic codes. If a +5 V diagnostic code becomes active, replace the ECM. If the ECM is replaced, the new ECM should be programmed

he same values and with the same parameter

with t as the suspect ECM.

STOP.

98 RENR2696-01 Troubleshooting Section

No – The +5 V sensor diagnostic code is no longer

•

active when the the harness or a sensor that is attached to the harness is causing the problem. Reconnect the ECM engine har Step 4.

Test Step 4. D While Active

harness is disconnected. Either

ness connector. Proceed to Test

isconnect The +5 V Sensors

Diagnostic Codes Are Being

Monitored.

A. Connect the electronic service tool to the

diagnostic

B. Turn the keyswitch to the ON position while the

engine is OF

C. Access the active diagnostic code screen on

the electro following diagnostic codes is active:

262-03 5 Vo

•

normal

262-04 5 Vo

•

normal

connector.

nic service tool. Verify that one of the

lt Sensor Supply voltage more than

lt Sensor Supply voltage less than

Repair: Reconnect the sensor that is suspected of causing the p after the reconnection of the sensor, disconnect the sensor. If the problem disappears after the disconnectio

Clear all diagnostic codes. Verify that the repair eliminates t

STOP.

roblem. If the problem returns

n of the sensor, replace the sensor.

he problem.

D. Disconnec

Engine oil pressure sensor J201/P201

•

Intake manifold pressure sensor J200/P200

•

E. Wait for 30

is disconnected while the electronic service tool is being monitored in order to verify that the disconne +5 V diagnostic code.

Note: Whe the keyswitch is in the ON position, open circuit diagnostic codes will be active or logged when the +5 V diagn normal. Clear these diagnostic codes after this test step is completed.

Expected Result:

The orig

Results:

Yes – The +5 V diagnostic code is still active. The

•

harness is the cause of the problem. Leave the sensors

t the following sensors one at a time:

seconds after each pressure sensor

ction of a specific sensor deactivates the

n the sensors are disconnected and

ostic codes are no longer active. This is

inal +5 V diagnostic code remains active.

disconnected. Proceed to Test Step 5.

No – The +5 V diagnostic code is not active when

•

a specif

ic sensor is disconnected.

RENR2696-01 99

Troubleshooting Section

Test Step 5. Check the Engine Harness.

Illustration 24

A. Turn the keyswitch to the OFF position whi le 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

•

P1:24EngineOilPressure

•

a. Wiggle the harness during the measurement in

order to reveal any intermittent short condition.

Expected Result:

Each resistance measurement is more than 20 ohms.

g00954709

Results:

OK –The+5Vlineisnotshortedintheengine

•

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:

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.

•

100 RENR2696-01 Troubleshooting Section

Check the operation of the air inlet heater starting

•

aid.

Also use this procedure if another procedure has directed you h

ere.

The air inlet heater starting aid is used to improve the engines’ abil

ity 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 11

00 Series engines. The 1104 uses glow

plugs. The 1106 uses a fuelled starting aid.

Illustration 25

Schematic for the air inlet heater starting aid

g00878524

Perkins Engine 1104E, 1106E Troubleshooting

Specifications and Main Features

Frequently Asked Questions

User Manual