Perkins Engine 1106D Troubleshooting Manual

Download

Page 1

This document is printed from SPI². Not for RESALE

Troubleshooting

KENR6201-01

February 2010

1106D El (EPG)

PJ (Engine)

ectric Power Generation

Page 2

This document is printed from SPI². Not for RESALE

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe 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 necessary training, skills and tools to perform these functions properly.

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

Do not operate or perform any lubrication, maintenance or repair on this product, until you have 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, bodily injury or death could occur to you or to other persons.

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! Become Alert! Your Safety is Involved.

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

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, 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 start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins

replacement parts.

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

death.

Page 3

This document is printed from SPI². Not for RESALE

KENR6201-01 3

Table of Contents

Troubleshooting Section

Electronic Troubleshooting

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

Glossary .................................................................. 7

Electronic Service Tools ......................................... 11

Indicator Lamps .................................................... 13

Replacing the ECM ............................................... 16

Self-Diagnostics .................................................... 17

Sensors and Electrical Connectors ....................... 17

Engine Wiring Information .................................... 21

ECM Harness Connector Terminals ..................... 24

Programming Parameters

Programming Parameters ..................................... 26

Test ECM Mode .................................................... 26

Factory Passwords ............................................... 26

Flash Programming .............................................. 27

Injector Trim File ................................................... 27

Speed Demand Input Setup ................................. 28

Customer Speciﬁed Parameters

Customer Speciﬁed Parameters ........................... 31

Customer Speciﬁed Parameters Table ................. 34

Customer Speciﬁed Parameters Worksheet ......... 35

System Conﬁguration Parameters

System Conﬁguration P arameters ........................ 36

Troubleshooting without a Diagnostic Code

Alternator Noise .................................................... 37

Alternator Will Not Charge .................................... 37

Battery .................................................................. 38

Can Not Reach Top Engine RPM ......................... 38

Coolant in Engine Oil ............................................ 40

Coolant Temperature Is Too High ......................... 41

ECM Will Not Accept Factory Passwords ............. 42

ECM Will Not Communicate with Other Systems or

Display Modules .................................................. 43

Electronic Service Tool Will Not Communicate with

ECM ................................ .................................... 43

Engine Cranks but Will Not Start .......................... 44

Engine Has Early Wear ........................................ 48

Engine Misﬁres, Runs Rough or Is Unstable ........ 49

Engine Oil in Cooling System ............................... 50

Engine Vibration ................................................... 51

Engine Will Not Crank ........................................... 52

Excessive Black Smoke ........................................ 53

Excessive Engine Oil Consumption ...................... 55

Excessive Fuel Consumption ............................... 56

Excessive Valve Lash ........................................... 58

Excessive White Smoke ....................................... 58

Intake Air Temperature Is Too High ...................... 59

Intermittent Engine Shutdown ............................... 61

Intermittent Low Power or Power Cutout .............. 62

Low Engine Oil Pressure ...................................... 63

Low Power ............................................................ 64

Mechanical Noise (Knock) in Engine .................... 66

Noise Coming from Cylinder ................................. 67

Troubleshooting with a Diagnostic Code

Diagnostic Cod

CID 0001 FMI 02 .................................................. 70

CID 0001 FMI 05 .................................................. 70

CID 0001 FMI 06

CID 0001 FMI 07 .................................................. 71

CID 0002 FMI 02 .................................................. 71

CID 0002 FMI 0

CID 0002 FMI 06 .................................................. 72

CID 0002 FMI 07 .................................................. 73

CID 0003 FMI

CID 0003 FMI 05 .................................................. 73

CID 0003 FMI 06 .................................................. 74

CID 0003 FMI

CID 0004 FMI 02 .................................................. 75

CID 0004 FMI 05 .................................................. 75

CID 0004 FM

CID 0004 FMI 07 .................................................. 76

CID 0005 FMI 02 .................................................. 76

CID 0005 FM

CID 0005 FMI 06 .................................................. 77

CID 0005 FMI 07 .................................................. 78

CID 0006 F

CID 0006 FMI 05 .................................................. 78

CID 0006 FMI 06 .................................................. 79

CID 0006 F

CID 0041 FMI 03 .................................................. 80

CID 0041 FMI 04 .................................................. 80

CID 0091

CID 0100 FMI 03 .................................................. 81

CID 0100 FMI 04 .................................................. 81

CID 0100

CID 0110 FMI 03 ................................................... 82

CID 0110 FMI 04 ................................................... 82

CID 016

CID 0168 FMI 01 .................................................. 83

CID 0168 FMI 02 .................................................. 84

CID 01

CID 0172 FMI 04 .................................................. 85

CID 0190 FMI 08 .................................................. 85

CID 02

CID 0253 FMI 02 .................................................. 86

CID 0261 FMI 11 ................................................... 86

CID 0

CID 0262 FMI 04 .................................................. 87

CID 0268 FMI 02 .................................................. 87

CID 0

CID 0526 FMI 05 .................................................. 88

CID 0526 FMI 06 .................................................. 88

CID

CID 1779 FMI 05 .................................................. 89

CID 1779 FMI 06 .................................................. 89

CID

CID 1785 FMI 03 .................................................. 90

CID 1785 FMI 04 .................................................. 90

CID 1797 FMI 03 .................................................. 91

CID 1797 FMI 04 .................................................. 92

CID 2246 FMI 06 .................................................. 92

roubleshooting with an Event Code

Event Codes ........................................................ 94

8 FMI 00 .................................................. 83

72 FMI 03 .................................................. 84

47 FMI 09 .................................................. 85

262 FMI 03 .................................................. 86

342 FMI 08 .................................................. 88

1690 FMI 08 .................................................. 89

1779 FMI 08 .................................................. 90

D 1785 FMI 10 .................................................. 91

D 1834 FMI 02 .................................................. 92

e Cross Reference ....................... 68

.................................................. 71

5 .................................................. 72

02 .................................................. 73

07 .................................................. 74

I 06 .................................................. 76

I 05 .................................................. 77

MI 02 .................................................. 78

MI 07 .................................................. 79

FMI 08 .................................................. 80

FMI 10 .................................................. 81

Page 4

This document is printed from SPI². Not for RESALE

4 KENR6201-01 Table of Contents

E085 Engine Shutdown Overridden ..................... 94

E255 Diagnosti

E264 Emergency Stop Activated .......................... 94

E360 Low Engine Oil Pressure ............................. 95

E361 High Engi

E362 Engine Overspeed ....................................... 97

E396 High Fuel Rail Pressure .............................. 98

E398 Low Fuel

E539 High Intake Manifold Air Temperature ......... 99

c Reset ......................................... 94

ne Coolant Temperature .............. 96

Rail Pressure ............................... 99

Diagnostic

5 Volt Sensor Supply Circuit - Test ..................... 101

CAN Data Link Circuit - Test ............................... 107

Data Link Ci

ECM Memory - Test ............................................. 116

Electrical Connectors - Inspect ............................ 117

Engine Pre

Test ................................................................... 121

Engine Speed/Timing Sensor Circuit - Test ........ 128

Engine Tem

Test ................................................................... 135

Fuel Rail Pump Solenoid - Test .......................... 140

Ignition

Test ................................................................... 144

Indicator Lamp Circuit - Test ............................... 150

Injector

Injector Solenoid Circuit - Test ............................ 156

Speed Control (Analog) - Test ............................ 163

Speed Co

Starting Aid (Glow Plug) Relay Circuit - Test ...... 168

Wastegate Solenoid - Test .................................. 172

Functional Tests

rcuit - Test ......................................... 110

ssure Sensor Open or Short Circuit -

perature Sensor Open or Short Circuit -

Keyswitch Circuit and Battery Supply Circuit -

Data Incorrect - Test ............................... 154

ntrol (PWM) - Test ............................... 166

Index Section

Index ................................................................... 177

Page 5

This document is printed from SPI². Not for RESALE

KENR6201-01 5

Troubleshooting Section

Electronic Troubleshooting

i03805210

System O verview

System Ope

ration

lustration 1

(1) Electronic Unit Injector (2) Solenoid for the Fuel Rail Pump (3) Wastegate Regulator (if equipped) (4) Secondary S peed/Timing Sensor (5) Fuel Rail Pump

(6) Primary Spee d/Timing Sensor (7) Intake Manifold Pressure Sensor (8) Fuel Rail Pressure S ensor (9) Engine O il Pressure Sensor (10) Intake Manifold Temperature Sensor

(11) Coolant Temperature Sensor (12) Diagnostic Connector (if equipped) (13) Electronic Control M odule (ECM)

g01808033

Page 6

This document is printed from SPI². Not for RESALE

6 KENR6201-01 Troubleshooting Section

The 1 106D engine was designed for electronic control. The en (ECM), a fuel rail pump and electronic unit injectors. All of these items are electronically controlled. There arealsoanumb engines can be equipped with an electronically controlled wastegate for the turbocharger. The ECM controls the the software within the ECM and the inputs from the various sensors. The software contains parameters that contro include all of the operating maps and customer selected parameters.

The electronic system consists of the ECM, the engine sensors and inputs from the parent machine. The ECM is t is the software for the computer. The personality module deﬁnes the following characteristics of the engine:

Engine power

•

Torque curves

•

Engine sp

•

Engine Noise

•

gine has an Electronic Control Module

er of engine sensors. Turbocharged

engine operating parameters through

l the engine operation. The parameters

he computer. The personality module

eed (rpm)

At start-up, the ECM determines the top center position of the speed/timing sensor in the fuel rail pump. The ECM decides when fuel injection should occur relative to the top center performance by control of each of the electronic unit injectors so that the required amount of fuel is injected at t electronic unit injectors are supplied high pressure fuel from the fuel rail. The ECM also provides the signal to th solenoid in the fuel rail pump controls a valve in the fuel rail pump. This valve controls the pressure in the fuel rai is diverted away from the fuel rail pump back to the fuel tank.

The ECM adjusts injection timing and fuel pressure for the best engine performance, the best fuel economy an Theactualtimingcanbeviewedwithanelectronic service tool. Also, the desired timing can be viewed with an el

number 1 cylinder from the secondary

position. The ECM optimizes engine

he precise point of the engine's cycle. The

e solenoid in the fuel rail pump. The

l. Fuel that is not required for the engine

d the best control of exhaust emissions.

ectronic service tool.

Fuel Injection

The personality module inside the ECM sets certain limits on the amount of fuel that can be injected.

Smoke and Emissions

•

Engine

The ECM determines the injection timing, the amount of fuel manifold pressure if an electronically controlled wastegate is installed on the turbocharger. These decis desired conditions at any given time.

The go engine speed to the actual engine speed. The actual engine speed is determined through the primary spee sensor. If the desired engine speed is greater than the actual engine speed, the governor injects more fuel

Speed Governor

that is delivered to the cylinders and the intake

ions are based on the actual conditions and the

vernor has software that compares the desired

d/timing sensor and the secondary speed/timing

in order to increase engine speed.

Timing Considerations

Fuel injection timing is determined by the ECM after considering input from the following components:

Engine coolant temperature sensor

•

e sensor for the intake manifold air temperature

•

The sensor for the intake manifold pressure

•

Speed/timing sensors

•

The Fuel Ratio Control Limit is a limit that is based on intake manifold air pressure and engine rpm. The FRC Lim to control the engine's exhaust emissions. When the ECM senses a higher intake manifold air pressure, the ECM manifold air pressure indicates that there is more air in the cylinder. When the ECM increases the FRC Limit

The Rated Fuel Limit is a limit that is based on the power The Rated Fuel Limit enables the engine power and torque outputs to conform to the power and torque curv

These limits are in the personality module and these limi

Dia

When the ECM detects an electronic system problem, the logs the diagnostic code in order to indicate the time of the problem's occurrence. The ECM also logs the nu codes are provided in order to indicate that the ECM has detected an electrical problem or an electronic

oblem with the engine control system. In some

pr cases, the engine performance can be affected when the condition that is causing the code exists.

it is used to control the air/fuel ratio in order

increases the FRC Limit. A higher intake

, the ECM allows more fuel into the cylinder.

rating of the engine and on the engine rpm.

es of a speciﬁc engine model.

ts cannot be changedby the operator.

gnostic Codes

ECM generates a diagnostic code. Also, the ECM

mber of occurrences of the problem. Diagnostic

peed control device

•

Page 7

This document is printed from SPI². Not for RESALE

KENR6201-01 7

Troubleshooting Section

If the operator indicates that a performance problem occurs, the dia of the problem. Use the electronic service tool to access the diagnostic codes. The problem should then be correc

gnostic code may indicate the cause

ted.

Event Codes

Event Codes are used to indicate that the ECM has detected an abnormal engine operating condition. The ECM will This does not indicate an electrical malfunction or an electronic malfunction. For example, if the temperatur than the permitted limit, then the ECM will detect the condition. The ECM will then log an event code for the condit

Programma

Certain parameters that affect the engine operation may be cha The parameters are stored in the ECM, and the parameters are protected from unauthorized changes by passwo Conﬁguration Parameters.

System C factory. System Conﬁguration Parameters affect emissions or power ratings within the engine. Factory passwor must be used to change the System Conﬁguration Parameters.

log the occurrence of the event code.

e of the coolant in the engine is higher

ion.

ble Parameters

nged with electronic service tools.

rds. These parameters are System

onﬁguration Parameters are set at the

ds must be obtained and factory passwords

Adaptive Trim – This is a software process that is performed in th that optimizes engine performance.

Alternating C

electric current that reverses direction at a regular interval that is reoccurring.

Before Top Center (BTC) – BTC is the 180 degrees of crankshaft rotation before the piston reaches the top dead cen rotation.

Breakout Ha

test harness that is designed to connect into the engine harness. This connection allows a normal circuit op provides a Breakout T in order to measure the signals.

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

CAN Data Link (see also J1939 CAN Data Link) –

The CAN Da port that is used for communication with other microprocessor based devices.

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

Communi

communication adapter provides a communication link between the ECM and the electronic service tool.

e Electronic Control Module (ECM)

urrent (AC) – Alternating current is an

ter position in the normal direction of

rness – A breakout harness is a

eration and the connection simultaneously

rcuit is typically used as a test circuit.

ta Link is a serial communications

cation Adapter Tool – The

Passwords

System Conﬁguration Parameters are protected by factory passwords. Factory passwords are calculated onaco Perkins distributors. Since factory passwords contain alphabetic characters, only an electronic service tool System C onﬁguration Parameters affect the power rating or the emissions.

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

mputer system that is available only to

may change System Conﬁguration Parameters.

i03805350

Glossary

Active Diagnostic Code – An active diagnostic

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

Component Identiﬁer (CID) – TheCIDisanumber that identiﬁes the speciﬁc component of the electronic

ol system that has experienced a diagnostic

contr code.

nt Temperature Sensor – The coolant

Coola

temperature sensor detects the engine coolant temperature for all normal operating conditions and

ngine monitoring.

for e

Data Link – The Data Link is a serial communication

that is used for communication with other devices

port such as the electronic service tool.

ate – Certain engine conditions will generate

Der

event codes. Also, engine derates may be applied. The map for the engine derate is programmed into

ECM software. The derate can be one or more of

the 3 types: reduction of rated power, reduction of rated engine speed, and reduction of rated machine speed

r OEM products.

Desired Engine Speed – The desired engine speed

input to the electronic governor within the ECM.

is The electronic governor uses the signal from the throttle position sensor, the engine speed/timing

ensor, and other sensors in order to determine the

s desired engine speed.

Page 8

This document is printed from SPI². Not for RESALE

8 KENR6201-01 Troubleshooting Section

Diagnostic Code – A diagnostic code is sometimes referred to as a electronic system malfunction.

Digital Senso

from the ECM is used as ground for the digital sensors.

Digital Sensors – Digital sensors produce a pulse width modulated signal. Digital sensors are supplied with power f

Digital Sensor Supply – The power supply for the digital sen

Direct Current (DC) – Direct current is the type of current th

DT, DT Connector, or Deutsch DT – This is a type of con connectors are manufactured by Deutsch.

Duty Cycl

Electronic Engine Control – The electronic

engine co The electronic engine control monitors the engine operation under all conditions. The electronic engine control conditions.

Electro

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

also controls the engine operation under all

nic Control Module (ECM) – The ECM

at is input from the sensors of the engine. The

fault code. These codes indicate an

rReturn –The common line (ground)

rom the ECM.

sors is provided by the ECM.

at ﬂows consistently in only one direction.

nector that is used on the engine. The

e–Refer to “Pulse Width Modulation”.

ntrol is a complete electronic system.

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

Failure Mode Identiﬁer (FMI) – This identiﬁer indicates the type of failure that is associated with the componen SAE practice of J1587 diagnostics. The FMI follows the parameter identiﬁer (PID) in the descriptions of the fault co the following list.

0–The data i operational range.

1–The data operational range.

2–The data

3–The voltage is above normal or the voltage is

shorted h

4–The voltage is below normal or the voltage is shorted l

5–The current is below normal or the circuit is open.

6–The current is above normal or the circuit is

grounded.

7–The mechanical system is not responding properly.

8–There is an abnormal frequency, an abnormal pulse width, or an abnormal time period.

cate an abnormal engine operating

t. The FMI has been adopted from the

de. The descriptions of the FMIs are in

s valid but the data is above the normal

isvalidbutthedataisbelowthenormal

is erratic, intermitte nt, or incorrect.

igh.

ow.

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

Engine Monitoring – Engine Monitoring is the part

e electronic engine control that monitors the

of th sensors. This also warns the operator of detected problems.

Engine Oil Pressure Sensor – The engine oil pressure sensor measures engine oil pressure. The

sor sends an electronic signal to the ECM that is

sen dependent on the engine oil pressure.

ine Speed/Timing Sensor – An engine

Eng

speed/timing sensor is a hall effect switch that provides a signal to the ECM. The ECM interprets

is signal as the crankshaft position and the engine

th speed. Two sensors are used to provide the speed and timing signals to the ECM. The primary sensor

associated with the crankshaft and the secondary

is sensor is associated with the camshaft.

ther Relay – Theetherrelayisusedtoactuatethe

ether injection system. The ECM controls the relay.

9–There has been an abnormal update.

10 – Th

11 – The failure mode is not identiﬁable.

12 – The device or the component is damaged.

13 – T

14 and 15 – These locations are reserved for a

fut

Flash Programming – Flash programming is the met an electronic service tool over the data link instead of replacing components.

Fuel Injector E-Trim – Fuel injector E-trim is a software process that allows precise control of fuel in the ECM for each fuel injector. With the use of the electronic service tool, the service technician can

ead status information for the E-Trim. Data for

r E-Trimcanalsobeprogrammed.

ere is an abnormal rate of change.

he device or the component is not calibrated.

ure assignment.

hod of programming or updating an ECM with

jectors by parameters that are programmed into

Page 9

This document is printed from SPI². Not for RESALE

KENR6201-01 9

Troubleshooting Section

FRC – See “Fuel Ratio Control”.

Fuel Pump – See “Fuel Rail Pump”.

Fuel Rail – Thi

the High Pressure Fuel Rail. The fuel rail supplies fuel to the electronic unit injectors. The fuel rail pump and the fuel r in order to maintain the desired fuel pressure in the fuel rail. This pressure is determined by calibration of the engin emissions and performance requirements.

FuelRailPr

sensor sends an electronic signal to the ECM that is dependent on the pressure of the fuel in the fuel rail.

Fuel Rail Pump – This item is sometimes referred toastheHighPressureFuelRailPump.Thisisa device tha rail (high pressure fuel rail).

Fuel Rail

referred to as the High Pressure Fuel Rail Pump Solenoid Valve. This is a control device in the high pressure pressure in the fuel rail by using this valve to divert excess fuel from the pump to the fuel tank.

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

ses the FRC Limit (more fuel into the cylinder).

increa

Full Load Setting (FLS) – The FLS is the number

epresents the fuel system adjustment. This

that r adjustment is made at the factory in order to ﬁne tune thefuelsystem.Thecorrectvalueforthisparameter

mped on the engine information ratings plate.

is sta This parameter must be programmed.

Plug – The glow plug is an optional starting aid

Glow

for cold conditions. One glow plug is installed in each combustion chamber in order to improve the ability of

ngine to start. The ECM uses information from

the e the engine sensors such as the engine temperature to determine when the glow plug relay must provide

er to each glow plug. Each of the glow plugs

pow then provides a very hot surface in the combustion chamber in order to vaporize the mixture of air and

l. This improves ignition during the compression

fue stroke of the cylinder.

ow Plug Relay – The glow plug relay is controlled

by the ECM in order to provide high current to the glow plugs that are used in the starting aid system.

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

ystem.

s item is sometimes referred to as

ail pressure sensor work with the ECM

e in order to enable the engine to meet

essure Sensor – Thefuelrailpressure

t supplies fuel under pressure to the fuel

Pump Solenoid Valve – This is sometimes

fuel rail pump. The ECM controls the

s used for purposes of emission control.

Hertz (Hz) – Hertz is the measure of electrical frequency in cy

High Pressure Fuel Rail Pump – See “Fuel Rail Pump”.

High Pressure Fuel Rail Pump Solenoid Valve –

See “Fuel Rai

High Pressure Fuel Rail – See “Fuel Rail”.

Injector Codes – The injector codes or injector trim

codes are numeric codes or alphanumeric codes that are etc unit injectors. These codes are used to ﬁne tune the fuel delivery.

Injector Trim Files – Injector trim ﬁles are downloaded from a disk to the ECM. The injector trim ﬁles compe the electronic unit injector. The serial number for the electronic unit injector must be obtained in order to retrieve

Intake Manifold Air Temperature Sensor – The intake ma air temperature in the intake manifold. The ECM monitors the air temperature and other data in the intake m other performance functions.

Intake M

Manifold Pressure Sensor measures the pressure in the intake manifold. The pressure in the intake manifo the engine (atmospheric pressure). The difference in pressure may be caused by an increase in air press

Integrated Electronic Controls – The engine is desig part of the system. The engine will not operate without the electronic controls.

J1939 CAN Data Link – This data link is a SAE standard diagnostic communications data link that is us electronic devices.

Log

codes are codes which are stored in the memory. These codes are meant to be an indicator of possible cau term “Diagnostic Code” in this glossary for more information.

OEM – OEM is an abbreviation for the Original Equipment Manufacturer. This is the manufacturer of th

the correct injector trim ﬁle.

ld may be different to the pressure outside

ure by a turbocharger (if equipped).

ned with the electronic controls as a necessary

ed to communicate between the ECM and the

ged Diagnostic Codes – Logged diagnostic

ses for intermittent problems. Refer to the

e machine or the vehicle that uses the engine.

cles per second.

l Pump Solenoid Valve”.

hed or stamped on individual electronic

nsate for variances in manufacturing of

nifold air temperature sensor detects the

anifold in order to adjust injection timing and

anifold Pressure Sensor –

The Intake

Page 10

This document is printed from SPI². Not for RESALE

10 KENR6201-01 Troubleshooting Section

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

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

Password – A characters or a group of alphanumeric characters that is designed to restrict access to parameters. The electronic to change some parameters (Factory Passwords). Refer to Troubleshooting, “Factory Passwords” for more infor

Personality Module – This module is software that is ins instructions (software) for the ECM and the module contains the performance maps for a speciﬁc engine. The perso through ﬂash programming.

Power Cyc

of cycling the keyswitch from any position to the OFF position, and to the START/RUN position.

Primary Speed/Timing Sensor – This sensor determines the position of the crankshaft during engine o sensor fails during engine operation, the secondary speed/timing sensor is used to provide the signal.

Pulse Width Modulation (PWM) – The PWM is a signal that consists of pulses that are of variable width of “TIME ON” versus total “TIME OFF” can be varied. Thisratioisalsoreferredtoasadutycycle.

system requires correct passwords in order

mation.

ide the ECM. The module contains all the

nality module may be reprogrammed

peration. If the primary speed/timing

. These pulses occur at ﬁxed intervals. The ratio

n switch, or by an electrical wire

nded destination.

ble. This helps determine speciﬁc

password is a group of numeric

ling – Power cycling refers to the action

Rated Fuel Limit – This is a limit that is based on

the power ratin The Rated Fuel Limit enables the engine power and torque outputs to conform to the power and torque curves of a spe in the personality module and these limits cannot be changed.

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

Relay – A relay is an electromechanical switch. A

ﬂow of electricity in one circuit is used to control the ﬂow of elec

voltage is applied to a relay in order to switch a much larger current or voltage.

Secondary Speed/Timing Sensor – This sensor determines the position of the camshaft during engine operatio during engine operation, the secondary speed/timing sensor is used to provide the signal.

Sensor – A sensor is a device that is used to detect the current value of pressure or temperature, or mecha detected is converted into an electrical signal.

Short Ci

an electrical circuit that is inadvertently connected to an undesirable point. An example of a short circuit is a wir this rubbing eventually wears off the wire insulation. Electrical contact with the frame is made and a short circu

Signal – The signal is a voltage or a waveform that is use asensortotheECM.

e which rubs against a vehicle frame and

it results.

d in order to transmit information typically from

g of the engine and on the engine rpm.

ciﬁc engine model. These limits are

the ECM to a sensor. The reference

tricity in another circuit. A small current or

n. If the primary speed/timing sensor fails

nical movement. The information that is

rcuit – A short circuit is a condition that has

dDemandInput –The speed demand input is

Spee

a signal that is sent to the ECM in order to calculate desired engine speed.

Supply Voltage – The supply voltage is a continuous voltage that is supplied to a component in order to

vide the electrical power that is required for the

pro component to operate. The power may be generated by the ECM or the power may be battery voltage that

upplied by the engine wiring.

is s

System Conﬁguration Parameters – System

nﬁguration parameters are parameters that affect

co emissions and/or operating characteristics of the engine.

Illustration 2

g00284479

Page 11

This document is printed from SPI². Not for RESALE

KENR6201-01 11

Troubleshooting Section

Tattletale – Certain parameters that affect the operation of th These parameters can be changed by use of the electronic service tool. The tattletale logs the number of changes tha ThetattletaleisstoredintheECM.

Throttle Pos

interpretation by the ECM of the signal from the speed controller.

Timing Calibration – The timing calibration is the adjustment of an electrical signal. This adjustment is made in orde camshaft and the engine speed/timing sensors or between the crankshaft and the engine speed/timing sensors.

Top Center Position – The top center position refers to the cran position is at the highest point of travel. The engine must be turned in the normal direction of rotation in order to r

T otal Tattletale – The total tattletale is the total number of stored in the ECM.

Wastega

engine that controls the maximum boost pressure that is provided to the inlet manifold.

Wastegate Regulator (if equipped) – The wastegate regulator controls the pressure in the

manifold to a value that is determined by the

intake ECM. The wastegate regulator provides the interface between the ECM and the mechanical system that

ates intake manifold pressure to the desired

regul value that is determined by the software.

e engine are stored in the ECM.

t have been made to the parameter.

ition – The throttle position is the

r to correct the timing error between the

kshaft position when the engine piston

each this point.

changes to all the parameters that are

te – This is a device in a turbocharged

Required Service Tools

Table 1

Required Service Tools

Part Number Description

CH11155

2900A019

27610285

Two short jumper wires are needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector. A long extension wire may also be needed to check the continuity of some wiring harness circuits.

Crimp Tool (1

Wire Removal Tool

Removal To ol

Suitable Digital Multimeter

2−AWG TO 18−AWG)

Optional Service Tools

Table 2 lists the optional service tools that can be used when the engine is serviced.

Table 2

Part Number Description

U5MK1092

28170107

2900A038

Spoon Probe Kit(MULTIMETER)

Suitable Digital Pressure Indicator or Engine Pressure Group

ble Battery Load Tester

Suita

Suitable Temperature Adapter (MULTIMETER)

Bypass Harness As

Harness As

i02517580

Electronic Service Tools

Perkins electronic service tools are designed to help the service technician:

Retrieve diagnostic codes.

•

Diagnose electrical problems.

•

Read parameters.

•

Program parameters.

•

Install trim ﬁles.

•

Perkins Electronic Service Tool

The Perkins Electronic Service Tool can display the following information:

Status of all pressure sensors and temperature

•

sensors

Programmable parameter settings

•

Active diagnostic codes and logged diagnostic

•

codes

Logged events

•

Histograms

•

The Electronic Service Tool can also be used to perform the following functions:

Diagnostic tests

•

Page 12

This document is printed from SPI². Not for RESALE

12 KENR6201-01 Troubleshooting Section

Sensor calibrations

•

Programming of ﬂash ﬁles

•

Parameter pro

•

Copy conﬁguration function for ECM replacement

•

Data logging

•

Graphs (rea

•

gramming

ltime)

Table 3 lists the service tools that are required in order to use

Table 3

Service Tools for the Use of the Electronic

Part

Number

27610251

27610164

(1)

Refer to Perkins Engine Company Limited.

the Electronic Service Tool.

Service Tool

(1)

Single Use Program License

Data Subscription for All Engines

Communication Adapter (Electronic Service

Adapter Cable As

Tool to ECM interface)

Description

Connecting the Electronic Service Tool and the Communi

cation Adapter II

Note: For more information regarding the use of the

Electronic Service Tool and the PC requirements for the Electronic Service Tool, refer to the documentation that accompanies your Perkins Electronic Service Tool software.

Illustration 3

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

g01121866

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

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

1. Turn the keyswitch to the OFF position.

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

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

Note: The Adapter Cable Assembly (4) is required to connect to the USB port on computers that are not equipped with a RS232 serial port.

3. Connect cable (4) between the “DATA LINK” end of communication adapter (3) and the service tool connector.

4. Place the keyswitch in the ON position. If the Electronic Service Tool and the communication adapter do not communicate with the Electronic Control Module (ECM), refer to the diagnostic procedure Troubleshooting, “Electronic Service Tool Will Not Communicate With ECM”.

Page 13

This document is printed from SPI². Not for RESALE

KENR6201-01 13

Troubleshooting Section

i03787449

Indicator Lamps

Indicator Lam

The functions of the indicator lamps are designed to display the m minimum number of lamps.

Eight lamps lamp and the “Warning” lamp will normally be installed in the application. Dedicated optional lamps for other it optional lamps are “Low oil pressure”, “Overspeed”, “High Coolant Temperature”, “Diagnostic”, “Derate” and “Maint

The “Shutdown” lamp and the “Warning” lamp can also be us the “Flash Code” feature. The “Flash Code” feature can be used to indicate all active diagnostic codes and logge

Functio

aximum amount of information on the

are available as options. The “Shutdown”

ems may also be installed. The remaining

enance”.

ed to indicate a diagnostic code by use of

d diagnostic codes.

ns of the Lamps

On – Thelampwillcomeonwhena“highcoolant

temperature” e and the “Shutdown” lamp may also come on.

Overspeed Lam

Lamp check – When the keyswitch is turned to

the ON positi seconds. The lamp will then go off unless the engine overspeeds.

On – Thelampwillcomeonwhenan“engine overspeed” event is detected. The “Warning” lamp and the “Shu

vent is detected. The “Warning” lamp

on,thelampwillcomeonfortwo

tdown” lamp may also come on.

Derate Lamp

Lamp check – When the keyswitch is turned to the

ON position, the lamp will come on for two seconds.

On – Thelampwillcomeonwhentheengineis derated.

Diagnostic Lamp

Lamp che

ON position, the lamp will come on for two seconds.

ck – When the keyswitch is turned to the

Shutdown Lamp

Lamp check – When the keyswitch is turned to the

ON position, the lamp will come on for two seconds. The lam warning.

On – Th the engine protection strategy has been reached.

Warni

Lamp check – When the keyswitch is turned to the

ON po Thelampwillthengooffunlessthereisanactive warning.

On – Thelampwillbeonwhenthewarninglevel has been reached.

pwillthengooffunlessthereisanactive

elampwillbeonwhentheshutdownlevelin

ng Lamp

sition, the lamp will come on for two seconds.

Low Oil Pressure

pcheck –When the keyswitch is turned to the

Lam

ON position, the lamp will come on for two seconds.

– Thelampwillcomeonwhenalowoilpressure

event is detected. The “Warning” lamp and the “Shutdown” lamp may also come on.

Flashin

code or an event code is active. Refer to “Flash Codes”.

g–Thelampwillﬂashwhenadiagnostic

Maintenance Lamp

Lamp ch

ON position, the lamp will come on for two seconds. The lamp will then go off unless maintenance is due.

On – The lamp will come on when maintenance is due.

eck – When the keyswitch is turned to the

Color of Lamps

Typically, the “Shutdown” lamp is colored red and the “Warning” lamp is colored amber. The other lamps

ptional.

are o

High Coolant Temperature Lamp

amp check – When the keyswitch is turned to the

ON position, the lamp will come on for two seconds.

Page 14

This document is printed from SPI². Not for RESALE

14 KENR6201-01 Troubleshooting Section

Operation of the I ndi cator Lamps

Table 4

Warning

Lamp

(Alert

Lamp)

On On On On

Off Off Off Off

On Off Flashing Off

On Off Flashi

On On Flashing Off

Off Off

Shutdown

Lamp

(Action

Lamp)

Diagnostic

Lamp

Flashing

Derate

Lamp

Off

Lamp State Description of the Indication Engine State

Lamp Check

No Faults With the engine in operation, there

Warning (Warning only)

Derate

(Warni and Derate)

Engine

down

shut (Warning and

tdown)

shu

Diagnostic (Diagnostic

ly)

When the keyswitch is switched on, the lamps come on for a period of 2 seconds and the lamps will then go off.

are no active warnings, diagnostic codes or event codes.

If the warn during engine operation, and the diagnostic lamp is ﬂashing , the lamps ind the warning values for the engine protection strategy have been exceeded active event code. However, the value has not been exceeded to a level th shutdown.

If both the warning lamp and the derate lamp come on during engine operation, and the diagnostic lamp is ﬂashing, the lamps indicate that one or more of the values for the engine protection strategy have been exceeded beyond the level that will cause an engine derate.

If both the warning lamp and the shutdown lamp come on during engine operation, and the diagnostic lamp is ﬂashing, the lamps indicate that one or more of the shutdown values for the engine protection strategy has been exceeded and there is an active event code.

When the diagnostic lamp ﬂashes during operation of the engine, the lamp indicates that an active diagnostic code (an electrical fault) is present. However, the diagnostic code is not serious enough to cause a derate or a shutdown.

ing lamp comes on

icate that one or more of

and that there is an

at will cause a derate or a

The keyswitch is on but the engine has not yet been cranked.

The engine is operating with no detected faults.

The engine is operating normally. However, there is oneormoreofthe monitored engine parameters that are outside of the range that is acceptable.

The engine

ating.

is oper However, one or more of the

red engine

monito parameters is outside of the

table range.

accep The acceptable range has been

ded to

excee alevelwhich requires a warning

nengine

and a derate.

The engine is

er shutdown

eith or an engine shutdown is

inent.

imm One or more monitored engine

ameters have

par exceeded the limit for an engine

utdown.

The engine is operating but

ere is one or

th more faults with the electronic

ystem for the

s engine.

(continued)

Page 15

This document is printed from SPI². Not for RESALE

KENR6201-01 15

Troubleshooting Section

(Table 4, contd

Off Off Flashing On

Off On Flashing Off

)

Derate (Diagnostic and Derate)

Engine Shutdown

Flash Codes

The “Flash Code” feature is used to ﬂash the two digit code of all active diagnostic and event codes. Refer to the Troubleshooting Guide, “Diagnostic Codes” for the ﬂash code that is related to the diagnostic code or an event.

If the derate lamp comes on during engine operation, and the diagnostic lamp is ﬂashing, the lamps indicate that an active diagnostic code (an electrical fault) is present. The diagnostic code is serious enough to cause an engine derate.

If the shutdown lamp comes on during engine operation, and the diagnostic lamp is ﬂashing, this indicates that an active diagnostic code (an electrical fault) is present. The diagnostic code is serious enough to cause the engine to shutdown.

The engine is operating. However, an active diagno code is causing an engine derate.

The engine is either shutdown or an engine shutdown is imminent. A serious diagnostic code is active.

stic

When a diagnostic code or an event code is active or logged, the diagnostic lamp will ﬂash repeatedly in order to indicate the codes.

Each ﬂash will be on for half a second and off for 300 milliseconds. The “Diagnostic” lamp will remain off for two seconds between each digit of a code. If there is more than one diagnostic code, the “Diagnostic” lamp will go off for ﬁve seconds. The lamp will then ﬂash in order to indicate the next code.

As an example, an active diagnostic code of “21” is indicated by the “Diagnostic” lamp coming on for 500 ms, then off for 300 ms, then on for 500 ms, then off for 2000 ms, then on for 500 ms and then off.

Illustration 4

Once all codes have been ﬂashed, the “Diagnostic” lamp will go off for a period of 15 seconds before

Note: Flash codes are always sent in ascending numerical order.

g02048816

starting the sequence again.

Page 16

This document is printed from SPI². Not for RESALE

16 KENR6201-01 Troubleshooting Section

i03805671

Replacing the ECM

NOTICE Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjust collect the ﬂuid with suitable containers before opening any compartment or disassembling any component contai

Dispose of all ﬂuids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

ing and repair of the product. Be prepared to

ning ﬂuids.

NOTICE

the troubleshooting procedures in this manual

f the problem.

Note: When a new ECM is not available, an ECM canbeusedfrom The ECM must have the same serial number sufﬁx. Ensure that the replacement ECM and the part number fo ECM. Be sure to record the parameters from the replacement ECM. Use the “Copy Conﬁguration ECM Replacement

If the ﬂash ﬁle 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 diagnostic 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: Record any Logged Faults and Events for your records.

3. Record the following parameters:

an engine that is not in service.

rtheﬂash ﬁle match the suspect

” function in the electronic service tool.

NOTICE

Note: Ensure that the ECM is receiving power

at the ECM is properly grounded before

and th replacement of the ECM is attempted. Refer to the schematic diagram.

A test ECM can be used in order to determine if the ECM on the engine is faulty. Install a test ECM in

e of the suspect ECM. Install the ﬂash ﬁle with

plac the correct part number into the test ECM. Program the parameters for the test ECM. The parameters

match the parameters in the suspect ECM.

must Refer to the following test steps for details. If the test ECM resolves the problem, reconnect the suspect

. Verify that the problem returns. If the problem

ECM returns, replace the ECM.

e: If an ECM is intended to be used as a test

Not

ECM, “Test ECM Mode” must be selected on the electronic service tool before the engine serial

mber is entered.

Use the electronic service tool to read the parameters

the suspect ECM. Record the parameters in

in the suspect ECM. Install the ﬂash ﬁle into the new ECM. After the ECM is installed on the engine, the

arameters must be programmed into the new ECM.

Record all of th e parameters on the

•

“Conﬁguration” screen.

Record all of the parameters on the “Throttle

•

Conﬁguration” screen.

Record all of the p arameters on the “Mode

•

Conﬁguration” screen.

Record the serial numbers of the electronic unit

•

injectors. The injector serial numbers are shown on the “Injector Trim Calibration” 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 thePTMIdataonthePerkinsintranet.

4. Remove power from the ECM.

5. Remove the ECM. Refer to Disassembly and

Assembly, “Electronic Control Module - Remove and Install”.

6. Install the replacement ECM. Refer to Disassembly and Assembly, “Electronic Control Module Remove and Install”.

7. If the replacement ECM is intended to be used as a test ECM, select “Test ECM Mode” on the electronic service tool.

Page 17

This document is printed from SPI². Not for RESALE

KENR6201-01 17

Troubleshooting Section

8. Download the ﬂash ﬁle.

a. Connect the electronic service tool to the

diagnostic connector.

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

the electronic service tool.

c. Select the downloaded ﬂash ﬁle.

9. If necessar

the rating interlock. To clear the rating interlock, enter the factory password when the electronic service too ECM mode will also clear the rating interlock.

10. Use the ele parameters. Perform the following procedure.

a. If the “Cop

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

Note: During the following procedure, factory password

b. If the “Copy Conﬁguration” procedure failed,

conﬁgur parameters should match the parameters from step 3.

Perform the “Fuel System Veriﬁcation Test”.

11. Check f passwords are required to clear logged events.

y, use the electronic service tool to clear

lisﬁrst connected. Activating the Test

ctronic service tool to program the

yConﬁguration” procedure was

he ECM.

s may be required.

e the parameters individually. The

or logged diagnostic codes. Factory

Self-Diagnostics

i03538621

Logged

•

Active Code – An active diagnostic code indicates that an active fault has been detected by the control system. Activ Always service active codes prior to servicing logged codes.

Logged Code – Every generated code is stored in the permanent memory of the ECM. The codes are logged f cleared by use of the electronic service tool.

Event Code –

detection of an abnormal engine operating condition. For example, an event code will be generated if the oil pressu indicates the symptom of a fault.

Logged cod needed. The fault may have been temporary. The fault may have been resolved since the logging of the code. to generate an active diagnostic code whenever a component is disconnected. When the component is reconnec codes may be useful to help troubleshoot intermittent faults. Logged codes can also be used to review the perform

e codes require immediate attention.

or 100 operating hours unless a code is

An event code is generated by the

re is too low. In this case, the event code

es may not indicate that a repair is

If the system is powered, it is possible

ted, the code is no longer active. Logged

ance of the engine and the electronic system.

i03473503

Sensors and Electrical Connectors

The Electronic Control Module (ECM) and the sensors are located on the left side of the engine. RefertoFigure5.

The Electronic Control Module (ECM) has the ability to detect faults in the electronic system and with engine operation. A self-diagnostic check is also performed whenever power is applied to the ECM.

When a fault is detected, a code is generated. An alarm may also be generated. There are two types of codes:

Diagnostic codes

•

Event codes

•

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

Diagnostic codes can have two different states:

Active

•

Page 18

This document is printed from SPI². Not for RESALE

18 KENR6201-01 Troubleshooting Section

Illustration 5

Sensor locations

(1) Coolant Te mperature Sensor (2) Intake Manifold Temperature Sensor (3) Intake M anifold Pressure Sensor

(4) Fuel Rail Pressure S ensor (5) Electronic Control Module (ECM) (6) Oil Pressure S ensor

Note: If equipped, the wastegate regulator is installed on the right side of the engine.

g01811780

(7) Primary S peed/Timing Senso r (8) Secondary Speed/Timing Sens or (9) Solenoid for the Fuel Rail Pump

Page 19

This document is printed from SPI². Not for RESALE

KENR6201-01 19

Troubleshooting Section

Illustration 6

Detailed views of the sensor locations

g01811835

Page 20

This document is printed from SPI². Not for RESALE

20 KENR6201-01 Troubleshooting Section

Table 5

Connector

P532

P402

P401

P201

P228

P200 Intake Manifold Pressure Sensor (3 Pin Connector)

P103 Intake Manifold Temperature Sensor (2 Pin Connector)

P100 Coolant Temperature Sensor (2 Pin Connector)

J23

P691/J691 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin

P692/J692 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin

P693/J693 Electronic Unit Injectors for No. 5 and No. 6 Cylinders (4 Pin

P511

Machine Harness to ECM Connector (64 Pin Connector)

Engine Harness to ECM Connector (64 Pin Connector)

Fuel Rail Pump Solenoid Connector (2 Pin Connector)

Secondary Speed/Timing Sensor (2 Pin Connector)

Primary Speed/Timing Sensor (2 Pin Connector)

Engine Oil Pressure Sensor (3 Pin Connector)

Fuel Rail Pressure Sensor (3 Pin Connector)

Diagnos

Connector)

Wastegate regulator (if equipped) (2 Pin Connector)

tic Connector (if equipped)

Function

Page 21

This document is printed from SPI². Not for RESALE

KENR6201-01 21

Troubleshooting Section

Illustration 7

(1) Electronic Unit Injector (2) Solenoid for the Fuel Rail Pump (3) Wastegate Regulator (if equipped) (4) Secondary S peed/Timing Sensor (5) Fuel Rail Pump

(6) Primary Spee d/Timing Sensor (7) Intake Manifold Pressure Sensor (8) Fuel Rail Pressure S ensor (9) Engine O il Pressure Sensor (10) Intake Manifold Temperature Sensor

Engine Wiring Information

Harness Wire Identiﬁcation

i03805830

(11) Coolant Temperature Sensor (12) Diagnostic Connector (if equipped) (13) Electronic Control M odule (ECM)

Table 6

Color Codes for the Harness Wire

Color Code Color Color Code Color

BK Black BU Blue

BR Br

RD Red

own

PU Pu

GY Gray

g01808033

rple

Perkins identiﬁes all wires with eleven solid colors. The circuit number is stamped on the wire at a 25 mm (1 inch) spacing. Table 6 lists the wire colors and the

OR Orange

YL Yellow PK Pink

WH White

color codes.

GN Green

Page 22

This document is printed from SPI². Not for RESALE

22 KENR6201-01 Troubleshooting Section

For example, a wire identiﬁcation of F730-OR on the schematic w circuit number F730. F730-OR identiﬁes the power supply for the oil pressure sensor.

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

ould signify an orange wire with the

Page 23

This document is printed from SPI². Not for RESALE

KENR6201-01 23

Troubleshooting Section

Schematic Diagrams

Illustration 8

hematic Diagram for the Engine Harness

g01782875

Page 24

This document is printed from SPI². Not for RESALE

24 KENR6201-01 Troubleshooting Section

Illustration 9

Schematic Diagram for a Typical Application

i03434106

g02047353

ECM Harness Connector Terminals

The Electronic Control Module (ECM) uses connectors that have 64 terminals to interface to the wiring harness.

Illustration 10

ayout of the Connector Pins (view from the rear)

g01784773

Page 25

This document is printed from SPI². Not for RESALE

KENR6201-01 25

Troubleshooting Section

Removal and Installation of the Harness Connector Terminals

Terminal Removal

Table 7

Required Tools

Part Number Part Description Qty

27610285 Removal Tool 1

3. Insert the removal tool into the hole that is adjacent to the locking device.

Note: Make sur the face of the connector.

4. Hold the tool order to remove the terminal from the rear of the connector (3).

5. Remove the removal tool from the face of the connector (3).

Note: If a terminal must be replaced, part number 28170085 must be used.

terminal in order to release the

e that the tool stays perpendicular to

in position and gently pull the wire in

Terminal Insertion

1. Push the te

until the terminal engages with the locking device.

2. Gently pu the terminal is retained by the locking device.

3. Install components (2) into the sides of the connector (3).

rminal into the rear of the connector (3)

llonthewireinordertomakesurethat

the two terminal position assurance

Illustration 11

Removal of Terminal Position Assurance Components

1. Remove the connector from the ECM. Refer to Disassembly and Assembly, “Electronic Control Module - Remove and Install”.

2. Use a screwdriver that has a ﬂat blade (1) to remove the two terminal position assurance components (2) from the connector (3).

Note: Do not use the removal tool to remove the terminal position assurance components.

g01784793

4. Connect Disassembly and Assembly, “Electronic Control Module - Remove and Install”.

the connector to the ECM. Refer to

Illustration 12

Removal Tool

g01784822

Page 26

This document is printed from SPI². Not for RESALE

26 KENR6201-01 Troubleshooting Section

Programming Pa

rameters

i02415216

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.

i0343420

Test ECM Mode

“Test EC can be used to help troubleshoot an engine that may have a fault in the Electronic Control Module (ECM). This fe test ECM. This feature eliminates the need to stock atestECM.

M Mode” is a feature in the software that

ature allows a standard ECM to be used as a

Note: “Test ECM Mode” can only be activated if the engine seri programmed during normal operation of the ECM. If the engine serial number is programmed and the ECM is not in “T be used as a test ECM.

6. Use the “Copy electronic service tool to program the test ECM.

Note: If the used, program the test ECM with the values from the “Customer Speciﬁed Parameters Worksheet” and the values from

7. Program the engine serial number into the test ECM.

Note: The “Test ECM Mode” must be activated

before the the ECM.

8. Verify th

When the “Test ECM Mode” is activated, an internal timer set only while the ECM is powered and the keyswitch is in the ON position. After the ECM has counted down the ECM Mode”. The parameters and the engine serial number will be set.

al number has not already been

est ECM Mode”, the ECM can never

Conﬁguration” feature on the

“ECM Replacement” feature can not be

the System Conﬁguration Parameters.

engine serial number is programmed into

at the test ECM rectiﬁes the fault.

s a 24 hour clock. This clock will count down

24 hour period, the ECM will exit the “Test

1. Search for the latest ﬂash ﬁle for the engine.

If a newer software version is available for the

Note:

engine, install the newest software on the suspect ECM. If the new software does not rectify the fault,

inue with this procedure.

cont

2. Use the “Copy Conﬁguration” feature on the tronic service tool to copy the parameters

elec from the suspect ECM.

e: If the “ECM Replacement” feature cannot

Not

be used, record the programmed values into the “Customer Speciﬁed Parameters Worksheet”. Also

ord the system conﬁguration parameters.

rec

3. Disconnect the suspect ECM. Temporarily connect

e test ECM to the engine. Do not mount the test

th ECM on the engine.

ash program the test ECM with the newest

4. Fl

software that is available.

art the “Test ECM Mode” on the electronic

5. St

service tool. Access the feature through the “Service” menu. The electronic service tool will

isplay the status of the test ECM and the hours

d that are remaining for the “Test ECM Mode”.

If the test ECM rectiﬁes the fault, the engine can be released while the “Test ECM Mode” is still active.

Once an ECM has been activated in the “Test ECM Mode”, the ECM will stay in the “Test ECM Mode”

the timer times out. If the ECM is used as a test

until ECM for more than one engine, the “Test ECM Mode” must be reactivated. Anytime prior to the “Test ECM Mode”

timing out, the ECM can be reset to 24 hours.

i03434261

Factory Passwords

NOTICE Operating the engine with a ﬂash ﬁle not designed for that engine will damage the engine. Be sure the ﬂash ﬁle is correct for your engine.

Note: Factory passwords are provided only to Perkins dealers.

Factory passwords are required to perform each of the following functions:

Page 27

This document is printed from SPI². Not for RESALE

KENR6201-01 27

Troubleshooting Section

Program a new Electronic Control Module (ECM).

•

When an ECM is replaced, the system conﬁguration parameters must be programmed into the new ECM. A new ECM w be programmed once without factory passwords. After the initial programming, some parameters are protected by

Rerate the engine.

•

This may require changing the interlock code, which is protected by factory passwords.

Clear engine events and certain diagnostic codes.

•

Most engin order to clear the code from ECM memory. Clear these codes only when you are certain that a fault has been re Overspeed requires the use of factory passwords in order to clear the code from ECM memory.

Since factory passwords contain alphabetic characters, the electronic service tool must be used to pe factory passwords, proceed as if you already have the password. If factory passwords are needed, the elec passwords and the electronic service tool will display the information that is required to obtain the passwor

tronic service tool will request the factory

ds.

factory passwords.

e events require factory passwords in

ctiﬁed. For example, the E362-1 Engine

rform these functions. In order to obtain

ill allow these parameters to

i03807

Flash Programming

230

4. Select “WinFlash” from the “Utilities” menu on the

electronic ser

Note: If “WinFlash” will not communicate with the ECM, refer to T Tool Will Not Communicate with ECM”.

5. Program the ﬂ

a. Select the engine ECM under the “Detected

ECMs”.

b. Press the “Browse” button in order to select

the part num programmed into the ECM.

c. When the co

the “Open” button.

d. Verify tha

application. If the “File Values” do not match the application, search for the correct ﬂash ﬁle.

e. When the correct ﬂash ﬁle is selected, press

the “Begin Flash” button.

f. The electronic service tool will indicate

when programming has been successfully complet

6. Start the engine and check for proper operation.

7. Access the “Conﬁguration” screen under the

“Service” menu in order to determine the parame the “Tattletale” column. All of the parameters should have a tattletale of 1 or more. If a parameter has a t

vice tool.

roubleshooting, “Electronic Service

ash ﬁle into the ECM.

ber of the ﬂash ﬁle that will be

rrect ﬂash ﬁle is selected, press

t the “File Values” match the

ed.

ters that require programming. Look under

attletale of 0, program that parameter.

h Programming – A method of loading a ﬂash

Flas

ﬁle into the Electronic Control Module (ECM)

lectronic service tool can be utilized to program

The e a ﬂash ﬁle into the ECM. The programming transfers the ﬂash ﬁle from the PC to the ECM.

Flash Programming a Flash File

1. Obtain the part number for the new ﬂash ﬁle.

te: If you do not have the part number for the ﬂash

ﬁle, use “PTMI” on the Perkins Intranet.

te: You must have the engine serial number in

order to search for the part number for the ﬂash ﬁle.

nnect the electronic service tool to the service

2. Co tool connector.

urn the keyswitch to the ON position. Do not start

3.T

the engine.

“WinFlash” Error Messages

If you receive any error messages during programming, click on the “Cancel” button in order

op the process. Access the information about

to st the “ECM Summary” under the “Information” menu. Ensure that you are programming the correct ﬂash

or your engine.

ﬁle f

i03818309

Injector Trim File

The electronic service tool is used to load the injector trim ﬁles into the Electronic Control Module (ECM).

The injector trim ﬁles must be loaded into the ECM if any of the following conditions occur:

An electronic unit injector is replaced.

•

Page 28

This document is printed from SPI². Not for RESALE

28 KENR6201-01 Troubleshooting Section

The ECM is replaced.

•

Diagnostic code 268-2 is active.

•

Electronic un

•

cylinders.

Exchanging E

Exchanging electronic unit injectors can help determine i or in the cylinder. If two electronic unit injectors that are currently installed in the engine are exchanged between cyl be exchanged. Press the “Exchange” button at the bottom of the “Injector Trim Calibration” screen on the electroni injectors that will be exchanged and press the “OK” button. The tattletale for the electronic unit injectors that were e

Note: The serial number for the electronic unit injector electronic unit injector are located on the electronic unit injector.

1. Record the serial number and the conﬁrmation

2. Obtain the injector trim ﬁle by one of the following

3. Enter the serial number for the electronic unit

4. Download the injector trim ﬁle to the PC. Repeat

c service tool. Select the two electronic unit

and the conﬁrmation code number for the

code number for each electronic unit injector.

methods:

Select “Service Software Files” on the Perkins

•

Internet.

Use the compact disc that is included with a

•

replacement electronic unit injector.

injector in the search ﬁeld.

this procedure for each electronic unit injector, as

ired.

requ

it injectors are exchanged between

lectronic Unit Injectors

f a fault is in the electronic unit injector

inders, the injector trim ﬁles can also

xchanged will increase by one.

10. Select the appropriate injector trim ﬁle from the PC.

11. Click on the “Open” button.

12. If you are prompted by the electronic service

tool, enter the conﬁrmation code number for the electronic u

13. Click on the “OK” button.

The injector trim ﬁle is loaded into the ECM.

14. Repeat the p required.

Speed Dem

The 1106D engine can have a digital input that uses a Pulse Width Modulated (PWM) signal, an analog i communications port (J1939 Torque Speed Control (TSC1)). The Electronic Control Module (ECM) must be progr used. With certain types of primary input, a second input may be available.

The input is set up using the electronic service tool. From the menu, select “Services”. On the “Services” screen type of input from the following list:

•

, select “Throttle Conﬁguration”. Select the

Analo

PWM throttle

Communications port throttle (J1939 TSC1)

nit injector into the ﬁeld.

rocedure for each cylinder, as

i02453742

and Input Setup

nput or an input that is provided through a

ammed for the type of input that is being

g throttle

5. Connect the electronic service tool to the nostic connector. Refer to Troubleshooting,

diag “Electronic Service Tools”.

n the keyswitch to the ON position.

6. Tur

7. Select the following menu options on the electronic

vice tool:

ser

Service

•

Calibrations

•

jector Trim Calibration

•

8. Select the appropriate cylinder.

9. Click on the “Change” button.

Page 29

This document is printed from SPI². Not for RESALE

KENR6201-01 29

Troubleshooting Section

Table 9

Range

0 to 100 percent 0 percent

Default

Lower Position Limit

This is the minimum throttle percentage that will be interpreted by the ECM as zero throttle. This parameter is used with the value of initial lower position limit to make an allowance for manufacturing tolerances between different speed demand input devices.

Table 10

Range

0 to 100 percent 0 percent

Default

Illustration 13

Typical Range of Throttle

(1) Lower Diagnostic Limit (Default=5) (2) Lower Position Limit (Default=10) (3) Initial Low er Position (Default=20) (4) Lower Dead Z one % (Default=5) (5) Upper Dead Z one % (Default=5) (6) Initial Up per Position (Default=70) (7) Upper Position Limit (Default=85) (8) Upper Diagnostic Limit (Default=90)

g01224526

PWM inputs and communications port inputs do not require any additional programming. If an analog input is selected, the following parameters must be programmed into the ECM.

Lower Diagnostic Limit

This is the minimum throttle percentage that should be detected by the ECM in normal operation when the pedal is in the “off” position. A value below this limit will generate a short circuit diagnostic code. The range of this diagnostic detection area is from 0 percent to the programmed value for the lower position limit.

Table 8

Range Default

0 to 100 percent 0 percent

Upper Diagnostic Limit

This is the minimum throttle percentage that is detected by the ECM in normal operation when the pedal is in the maximum position. A value above this limit will generate an open circuit diagnostic code. The range of this diagnostic detection area is from the programmed value of the upper position limit to 100 percent.

Upper Position Limit

This is the maximum throttle percentage that will be interpreted by the ECM as full throttle. This parameter is used with the value of the initial upper position limit to make an allowance for manufacturing tolerances between different speed demand input devices.

Table 11

Range Default

0 to 100 percent 0 percent

Initial Lower Position Li mit

This is the maximum throttle percentage that will be interpreted by the ECM as zero throttle. This parameter is used with the value of the lower position limit to make an allowance for manufacturing tolerances between different speed demand input devices.

Table 12

Range Default

0to1

00 percent

0 per

cent

Initial Upper Position Limit

s is the minimum throttle percentage that will

Thi be interpreted by the ECM as zero throttle. This parameter is used with the value of the upper

sition limit to make an allowance for manufacturing

po tolerances between different speed demand input devices.

Page 30

This document is printed from SPI². Not for RESALE

30 KENR6201-01 Troubleshooting Section

Table 13

Range

0 to 100 percent 0 percent

Default

Lower Dead Zone

This is a throttle range above the initial lower position limit before the engine will increase in rpm.

Table 14

Range Default

0 to 100 percent 0 percent

Upper Dead Zone

This is a throttle range that is below the initial upper position limit that does not allow the engine speed to increase.

Table 15

Range Default

0 to 100 percent 0 percent

Page 31

This document is printed from SPI². Not for RESALE

KENR6201-01 31

Troubleshooting Section

Customer Speciﬁed Parameters

i03807232

Customer Speciﬁed Parameters

Customer speciﬁed parameters allow the engine to be conﬁgured to the exact needs of the application.

Customer parameters may be changed repeatedly as operational requirements change.

The following information is a brief description of the customer speciﬁed parameters. The following parameter values are included with the descriptions:

Minimum

•

Maximum

•

Default

•

Table 17

Value

17 digits

The available characters

are dependent on the

service tool that is

being used.

Default

Not programmed

Throttle Lock Parameters

Throttle Lock Feature Installation Status

The “Throttle Lock Feature Installation Status” is used to turn on the throttle lock features. When this parameter is changed to “Installed”, the “PTO engine Speed Setting”, the “Throttle Lock Increment Speed Ramp Rate” and the “Throttle Lock Engine Set Speed Increment” parameters are active and the parameters can be programmed.

Table 18

Value Default

Not Installed

Installed

Not Installed

Engine Rating Parameter

Rating Number

The rating number is the selected rating within a power rating family. The personality module deﬁnes the power rating family. The personality module can contain one to four ratings. The rating number deﬁnes the power rating that is used within the power rating family.

Table 16

Minimum Maximum

141

Default

ECM Identiﬁcation Parameter

Equipment ID

“Equipment ID” is the identiﬁcation of the equipment that is assigned by the customer. The “Equipment ID” is only for reference only by the customer. The “Equipment ID” is not required by the Electronic Control Module (ECM).

Throttle Lock Increment Speed Ramp Rate

The “Throttle Lock Increment Speed Ramp Rate” is the rate of engine acceleration when the PTO switch is held in the ACCELERATE position. If this parameter is set to “0”, the feature is turned off.

Table 19

Minimum Maximum Default

0 rpm/sec 600 rpm/sec 400 rpm/sec

Throttle Lock Engine Set Speed Increment

The “Throttle Lock Engine Set Speed Increment” controls the increase in engine speed when the

witch is brieﬂy operated to ACCELERATE or

PTO s DECELERATE. If this parameter is set to “0”, the feature is turned off.

le 20

Tab

Minimum Maximum Default

0 rpm 200 rpm 10 rpm

Page 32

This document is printed from SPI². Not for RESALE

32 KENR6201-01 Troubleshooting Section

Miscellaneous

Monitoring Mode Shutdowns

“Monitoring Mode Shutdowns” controls the shutdown feature that is associated with the engine monitoring feature. When code with a “-3” sufﬁx is detected, the engine will be shut down.

Table 21

this feature is enabled and an event

Value Default

Disabled

Enabled

Disabled

J1939 Continuous Fault Handling

Remote Torque Speed Control Enable Status

The “Remote Torque Speed Control Enable Status” parameter determines the way that faults will be handled by the ECM when the “J1939 Torque Speed Control (TSC1)” message is used as a speed request input to the ECM. Programming the “Remote Torque Speed Control Enable Status” to “Enabled” will cause theECMtodisplayafaultcodeifavalidTSC1 message is not received by the engine ECM within 30 seconds of the engine starting. If the“ Remote Torque Speed Control Enable Status” is programmed to “Disabled”, the engine will display a 247-12 Data Link malfunction immediately after a loss of a TSC1 message. Program “Remote Torque Speed Control Enable Status” to “Enabled” if the ECM will always be receivingaTSC1message.

Table 22

Value

Disabled

Enabled

Default

Disabled

Conﬁgurable Inputs

Overspeed Protection

The “Overspeed Protection” speed is the engine rpm when a shutdown will occur. Overspeed protection is used in order to protect the engine from damage. Overspeedprotectionmustbeenabledin“Monitoring Mode Shudowns”.

Table 23

Minimum Maximum

1500 rpm 2100 rpm 2100 rpm

Default

Conﬁgurable Governor Droop

“Conﬁgurable Governor Droop” allows the engine to run in “droop mode” when the genset is operated in parallel with

Table 24

Minimum Maximum Default

0 percent 8 percent 0 percent

other gensets.

Coolant Level Sensor

A coolant level sensor is an optional switch input. Programming the “Coolant Level Sensor” parameter to “Enabled” notiﬁes the ECM that a coolant level sensor input is present on pin J1:38. If this parameter is programmed to “Enabled” and the coolant level falls below the measured level, a “E2143-3” event code will be displayed.

Table 25

Value Default

Disabled Enabled

Disabled

Air Filter Restriction Switch Installation Status

An “Air Filter Restriction Switch” is an optional switch input. Programming the “Air Filter Restriction Switch Installation Status” parameter to “Enabled” notiﬁes the ECM that an input from the air ﬁlter restriction switch is present on pin J1:47. When this parameter is programmed to “Enabled” and the air ﬁlter restriction switch closes, an E172-1 or J107-15 event code will be displayed.

Table 26

Value

Disabled Enabled

Default

Disabled

Fuel/Water Separator Switch Installation Status

A fuel/water separator switch is an optional switch input. Programming the “Fuel/Water Separator Switch Installation Status” parameter to “Enabled” notiﬁes the ECM that a fuel/water separator switch input is present on pin J1:44. When this parameter is programmed to “Enabled” and the fuel/water separator switch closes, an E232-1 or J97-15 event code will be displayed.

Page 33

This document is printed from SPI². Not for RESALE

KENR6201-01 33

Troubleshooting Section

Table 27

Value

Disabled

Enabled

Default

Disabled

User Deﬁned Switch Installation Status

Auserdeﬁned shutdown switch is an optional switch input. Programming the “User Deﬁned Switch Installation Status” parameter to “Enabled” notiﬁes theECMthatauserdeﬁned switch input is present on pin J1:48. If this parameter is programmed to “Enabled” and the user deﬁned shutdown switch closes, the engine will shut down.

Table 28

Value Default

Disabled

Enabled

Disabled

Page 34

This document is printed from SPI². Not for RESALE

34 KENR6201-01 Troubleshooting Section

i02444244

Customer Speciﬁed Parameters Table

Table 29

Customer Speciﬁed Parameters

ECM Parameter

Engine Rating Parameter

“Rating Number”

ECM Identiﬁcation Parameter

“Equipment ID” 17 Digits

Throttle

“Throttle Lock Feature Installation Status”

“Throttle Lock Increment Speed Ramp Rate”

“Throttle Lock Engine Set Speed Increment”

Miscellaneous

“Monitoring Mode Shutdowns”

J1939 Continuous Fault Handling

“Remote Torque Speed Control Enable Status”

Conﬁgurable Inputs

“Overspeed Protection” 1500 to 2100 rpm 2100 rpm

“C

“Coolant Level Sensor”

“Air Filter Restriction Switch Installation Status”

“Fuel/Water Separator Switch Installation Status”

“User Deﬁned Switch Installation Status”

Lock Parameters

onﬁgurable Governor Droop”

Available characters are dependent on

Possible Values

1to4 1

the service tool that is used

Installed

Not Installed

0 to 600 rpm/sec 400 rpm/sec

0 to 200 rpm 10 rpm

Disabled

Enabled

Disabled

led

Enab

to 8%

Not Installed

Installed J1:38

ot Installed

Installed J1:47

Not Installed

Installed J1:44

Not Installed

Installed J1:48

Default Value

Not Progra

Not Installed

mmed

Disabled

ot Installed

Page 35

This document is printed from SPI². Not for RESALE

KENR6201-01 35

Troubleshooting Section

i02444245

Customer Speciﬁed Parameters Worksheet

Table 30

Customer Speciﬁed Parameters Worksheet

Engine Rating Parameter

“Rating Numbers”

ECM Identiﬁcations Parameters

“Equipment ID”

ock Parameters

Miscellaneous

“Throttle Lock Feature Installation Status”

“Throttle Lock Increment Speed Ramp Rate”

“Throttle Lock Engine Set Speed Increment”

“Monitoring Mode Shutdowns”

J1939 Continuous Fault Handling

“Remote Torque Speed Control Enable Status”

rspeed Protection”

“Ove

“Conﬁgurable Governor Droop”

“Coolant Level Sensor”

“Air Filter Restriction Switch Installation Status”

“Fuel/Water Separator Switch Installation Status”

“User Deﬁned Switch Installation Status”

Throttle L

Conﬁgurable Inputs

Page 36

This document is printed from SPI². Not for RESALE

36 KENR6201-01 Troubleshooting Section

System Conﬁguration Parameters

i03818369

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 Electronic Control Module (ECM) is replaced. System conﬁguration parameters do not need to be reprogrammed if the ECM software is changed. Factory passwords are required to change these parameters. The following information is a description of the system conﬁguration parameters.

Full Load Setting

The full load setting is a number that represents the adjustment to the fuel system that was made at the factory in order to ﬁne tune the fuel system. If the ECM is replaced, the full load setting must be reprogrammed in order to prevent a 268-2 diagnostic code from becoming active.

This code does not need to be programmed when the replacemen

If the ECM is for a different engine rating, then the following com pistons, fuel injectors, and other components. The engine information ratings plate must also be changed in or

Some systems such as the cooling system or the transmissi engine is rerated. Contact the application OEM for further information.

t ECM is for the same engine rating.

ponents may need to be changed:

der to reﬂect the new rating.

on may also require changes when the

Engine Serial Number

When a new ECM is delivered, the engine serial number in the ECM is not programmed. The engine serial num engine serial number that is stamped on the engine information plate.

ber should be programmed to match the

ECM Software Release Date

This parameter is deﬁned by the rating interlock and this parameter is not programmable. The ECM softwar of the software. The Customer parameters and the software change levels can be monitored by this date. Th (DEC08). DEC is the month (December). 08 is the year (2008).

e release date is used to provide the version

edateisprovidedinthemonthandtheyear

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 268-2 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 aspeciﬁc engine. Each horsepower rating and each emission certiﬁcation has a different code to all other horsepower ratings and emission certiﬁcations.

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

The engine will not run.

•

Diagnostic code 253-2 (Personality Module erratic,

•

intermittent or incorrect) will be active.

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

Page 37

This document is printed from SPI². Not for RESALE

KENR6201-01 37

Troubleshooting Section

Troubleshooti

ng without a

Diagnostic Code

i03858309

Alternator Noise

Note: This is not an electronic system fault.

Refer to Systems Operation, Testing and Adjusting for information on possible electrical causes of this condition.

Probable Causes

Alternator drive belt

•

Alternator mounting bracket

•

Alternator drive pulley

•

Alternator bearings

•

Alternator Bearings

Check for excessive play of the shaft in the alternator. Check for wear in the alternator bearings. The alternator is must be replaced if the bearings are worn. Refer to Disassembly and Assembly, “Alternator - Remove” and Disassem

a nonserviceable item. The alternator

bly and Assembly , “Alternator - Install”.

i03436581

Alternator Will Not Charge

Note: This is not an electronic system fault.

Probable Causes

Alternator drive belt

•

Automatic tensioner

•

Charging circuit

•

Alternator

•

Recommended Actions

Alternator Drive Belt

Inspect the condition of the alternator drive belt. If the alternator drive belt is worn or damaged, check that the drive belt and the pulley are correctly aligned. If the alignment is incorrect, investigate the cause of the misalignment. If the alignment is correct, replace the drive belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.

Alternator Mounting Bracket

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 belt and the alternator drive pulley are in alignment.

Alternator Drive Pulley

Remove the nut for the alternator drive pulley and then inspect the nut and the drive shaft. If no damage is found, install the nut and tighten the nut to the correct torque. Refer to Speciﬁcations, “Alternator and Regulator” for the correct torque.

Recommended Actions

Alternator Drive Belt

Inspect the condition of the alternator drive belt. If the alternator drive belt is worn or damaged, check that the drive belt for the alternator and the pulley are correctly aligned. If the alignment is incorrect, investigate the cause of the misalignment. If the alignment is correct, replace the drive belt. Refer to Disassembly and Assembly, “Alternator Belt Remove and Install”.

Automatic Tensioner

Check the tension on the alternator drive belt. If necessary, replace the automatic tensioner. Refer to Disassembly and Assembly, “Alternator - Remove” and Disassembly and Assembly, “Alternator - Install”.

Charging Circuit

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

Page 38

This document is printed from SPI². Not for RESALE

38 KENR6201-01 Troubleshooting Section

Alternator

Verify that the alternator is operating correctly. Refer to Systems Operation, Testing and Adjusting, “Alternator item. If the alternator is not operating correctly, the alternator must be replaced. Refer to Disassembly and Assembly Disassembly and Assembly , “Alternator - Install”.

Test”. The alternator is not a serviceable

, “Alternator - Remove” and

i03807312

Battery

Note: This is not an electronic system fault.

Probable Causes

Charging circuit

•

Battery

•

Auxiliary device

•

Can Not Reach Top Engin e RPM

Note: If this

Troubleshooting, “Low Power”.

Probable Causes

Diagnostic

•

ECM parameters

•

Signal for the Speed demand input

•

Air intake

•

Val ve la sh

•

Turbocharger

•

Fuel supp

•

fault occurs only under load, refer to

codes

and exhaust system

i03807352

Recommended Actions

Charging Circuit

If a fault in the battery charging circuit is suspected, refer to Troubleshooting, “Alternator Will Not Charge”.

Faulty Batte ry

1. Check that the battery is able to maintain a

charge. Refer to Systems Operation, Testing and Adjusting, “Battery - Test”.

2. If the battery does not maintain a charge,

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

Auxiliary Device

1. Check that an auxiliary device has drained the

battery by being left in the ON position.

2. Charge the battery.

3. Verify that the battery is able to maintain a charge

when all auxiliary devices are switched off.

Low compression (cylinder pressure)

•

Individual malfunctioning cylinders

•

Electro

•

Recomm

nic unit injectors

ended Actions

Diagnostic Codes

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

nuing with this procedure.

conti

ECM Parameters

1. Ensure that the fault is not an incorrectly

programmed parameter.

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

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

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

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

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

Page 39

This document is printed from SPI². Not for RESALE

KENR6201-01 39

Troubleshooting Section

7. If the repairs have not eliminated the faults proceed to “Thr Input”.

Signal f or the

1. Use the electronic service tool and observe the

signal for th

2. If the signal is erratic, refer to Troubleshooting, “Speed Cont Troubleshooting, “Speed Control (Digital) - Test”.

3. If the fault “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.

3. Check the

the following defects:

Blockag

•

ottle Signal for the Speed Demand

Speed Demand Input

e speed demand input.

rol (Analog) - Test” or refer to

has not been eliminated, proceed to

and Exhaust System

air intake and the exhaust system for

3. Check that the compressor housing for the turbocharger i

4. Check that the turbine housing for the turbocharger is free of dirt

5. Check that the turbine blades rotate freely in the turbocharge

6. Ensure that the wastegate on the turbocharger is adjusted co Testing and Adjusting, “Turbocharger - Inspect”. If the wastegate actuator is faulty, replace the wastegate a Assembly, “Turbocharger - Disassemble” and Disassembly and Assembly, “Turbocharger Assemble”

7. If necessary, replace the turbocharger. Refer to Disasse

- Remove” and Disassembly and Assembly, “Turbocharger - Install”.

8. Check that the repairs have eliminated the faults.

9. If the rep

to “Fuel Supply”.

s free of dirt, debris and damage.

, debris and damage.

rrectly. Refer to Systems Operation,

ctuator. Refer to Disassembly and

mbly and Assembly, “Turbocharger

airs have not eliminated the fault proceed

Restrictions

•

Damage to the air intake and exhaust lines and

•

hoses

4. Make all necessary repairs to the engine.

5. Ensure

6. If the fault has not been eliminated, proceed to

“Valv

that the repairs have eliminated the fault.

e Lash”.

Valve Lash

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

necessary. Refer to Systems Operation, Testing

djusting, “Engine Valve Lash - Inspect and

and A Adjust”.

e repair does not eliminate the fault proceed

2. If th to “Turbocharger”.

bocharger

Tur

Note: The turbocharger that is installed on this

ine is a nonserviceable item. If any mechanical

eng fault exists, except for the wastegate actuator, then the turbocharger must be replaced. The wastegate

tuator can be replaced.

1. Ensure that the mounting bolts for the turbocharger

e tight.

2. Check that the oil drain for the turbocharger is not

locked or restricted.

Fuel Sup

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

gauge m

2. Ensure that the fuel supply valve is in the full OPEN po

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

4. Visually inspect the fuel supply lines for restr

5. Check that the low pressure fuel lines are tight and s

6. Remove the fuel ﬁlters. Inspect the fuel ﬁlters for cont Operation and Maintenance Manual, “Fuel System Filter- Replace and Fuel System Primary Filter (Wa the cause of the contamination.

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

8. Check for air in the low pressure fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in

9. Ensure that the fuel system has been primed.

efer to Systems Operation, Testing and

R Adjusting, “Fuel System - Prime”.

ply

ay be faulty.

sition.

lidiﬁed fuel (wax).

ictions.

ecured properly.

amination. Install new fuel ﬁlters. Refer to the

ter Separator) Element - Replace”. Determine

ck the diesel fuel for contamination. Refer to

Fuel - Test”.

Page 40

This document is printed from SPI². Not for RESALE

40 KENR6201-01 Troubleshooting Section

10. Check the fuel pressure. Refer to Systems Operation, Tes Pressure - Test”.

Contact with high pressure fuel may cause ﬂuid penetration and burn hazards. High pressure fuel spray may low these inspection, maintenance and service instructions may cause personal injury or death.

Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.

11. If the high pressure fuel lines have a leak, the high pressure fuel lines must be replaced. Refer to Disassembly and Assembly, “Fuel injection lines Remove and Fuel injection lines - Install”.

12. If the repairs do not eliminate the fault, proceed to “Low Compression (Cylinder P ressure)”.

ting and Adjusting, “Fuel System

cause a ﬁre hazard. Failure to fol-

NOTICE

Low Compression (Cylinder Pressure)

1. Perform a compression test. Refer to Systems

Operation, Testing and Adjusting, “Compression

-Test”.

2. If low compression is noted on any cylinders, investigate the cause and rectify the cause.

Individual M alfunctioning Cylinders

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

electronic service tool to isolate one cylinder at a time. Note if speed. If a reduction in engine speed is not noted, the isolated cylinder is not operating under normal conditions. results in a reduction of engine speed that is less than normal, this may indicate that the cylinder is operating b the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylin performance.

2. If all cyli faults were detected proceed to “Electronic Unit Injectors”.

there is any reduction in engine

If the isolation of a particular cylinder

elow normal performance. Investigate

der that is operating below normal

nders have been checked and no

Electronic Unit Injectors

1. With the e

electronic service tool to isolate one cylinder at a time. Note if there is any reduction in engine speed. I the isolated electronic unit injector is not operating under normal conditions. If the isolation of a particu speed that is less than normal, this may indicate that the electronic unit injector is operating below normal

2. Remove the electronic unit injector from the suspec Assembly, “Electronic Unit Injector - Remove”.

ngine speed at a fast idle, use the

f a reduction in engine speed is not noted,

lar cylinder results in a reduction of engine

performance.

t cylinder. Refer to Disassembly and

Possible causes of low compression are shown in the following list:

Loose glow plugs

•

Faulty piston

•

Faulty piston rings

•

Worn cylinder bores

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

3. Perform all necessary repairs.

4. Ensure that the repairs have eliminated the faults.

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

“Individual Malfunctioning Cylinders”.

3. Insta

4. Repeat the test in 1. If the fault is still apparent,

ll a new electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install”.

remove the replacement electronic unit injector

nstall the original electronic unit injector.

and i Refer to Disassembly and Assembly, “Electronic Unit Injector - R emove” and Disassembly and

mbly, “Electronic Unit Injector - Install”.

Asse

i03807529

Coolant in Engine Oil

Note: This is not an electronic system fault.

Probable Causes

Engine oil cooler

•

Cylinder head gasket

•

Page 41

This document is printed from SPI². Not for RESALE

KENR6201-01 41

Troubleshooting Section

Cylinder head

•

Cylinder block

•

Recommended Actions

Engine Oil Coo

1. Drain the engine lubricating oil from the engine.

2. Check for leaks in the oil cooler assembly. Refer

to Systems Operation, Testing and Adjusting, “Cooling Sy leak is found, install a new oil cooler. Refer to Disassembly and Assembly, “Engine Oil Cooler

- Remove” a “Engine Oil Cooler - Install” for the correct procedure.

Cylinder Head Gasket

1. Remove th

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

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

3. To ﬁt a new cylinder head gasket, refer to Disassembly and Assembly, “Cylinder Head -

” for the correct procedure.

Install

ler

stem” for the correct procedure. If a

nd Disassembly and Assembly,

e cylinder head. Refer to Disassembly

Cylinder Block

Inspect the top face of the cylinder block for faults and signs of leakage. If a fault is found, replace the cylinder b determine the cause of the leakage. Refer to Systems Operation, Testing and Adjusting, “Cylinder Block Inspect” for

lock. If signs of leakage are found,

the correct procedure.

Assembly after Repair

1. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.

2. Remove the oil ﬁlter element. Install a new engine oil ﬁlter element. Fill the engine with clean engine oil to the c and Maintenance Manual, “Engine Oil and Filter

- Change” for more information.

orrect level. Refer to the Operation

i03438642

Coolant Tem perature Is Too High

Note: This is not an electronic system fault.

Probable Causes

4. If there was no obvious signs of a faulty head

gasket

proceed to “Cylinder Head”.

Cylinder Head

1. Check the cylinder head for ﬂatness. Refer

to Systems Operation, Testing and Adjusting,

nder Head - Inspect” for the correct procedure.

“Cyli

2. Check the mating face of the cylinder head aults and signs of leakage. If a fault is

for f found, replace the cylinder head. If signs of leakage are found, determine the cause of the

age. Refer to Systems Operation, Testing and

leak Adjusting, “Cylinder Head - Inspect” for the correct procedure.

3. Check the internal core plugs in the cylinder head

for signs of leakage.

4. If the cylinder head is ﬂat and if the cylinder head

does not have any faults, refer to “Cylinder Block”.

Radiator ﬁns

•

Coolant level

•

Radiator cap and/or pressure relief valve

•

Coolant temperature gauge

•

Restriction in the coolant system

•

Water temperature regulator

•

Engine cooling fan

•

Coolant pump

•

Cylinder head gasket

•

Recommended Actions

Radiator Fins

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

Page 42

This document is printed from SPI². Not for RESALE

42 KENR6201-01 Troubleshooting Section

Coolant Level

1. Inspect the coolant level. If necessary, add

coolant.

2. Check the cooling system for leaks. Repair any

leaks immediately.

Radiator Cap and/or Pressure Relief Valve

1. Pressure test the cooling system. Refer to

Systems Operation, Testing and Adjusting, “Cooling Sy

2. Check that the seating surfaces of the pressure

relief val undamaged.

3. Check oper

and/or the radiator cap. If necessary, clean the components and/or replace the components.

stem” for the correct procedure.

ve and the radiator cap are clean and

ation of the pressure relief valve

Coolant Temperature Gauge

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

the reading for the coolant temperature

Restriction in t he Coolant System

1. Visual

ly inspect the cooling system for collapsed

hoses and/or other restrictions.

3. Check the engine cooling fan for damage. If necessary, rep and Assembly, “Fan - Remove and Install”.

lace the fan. Refer to Disassembly

Coolant Pump

1. Inspect the impeller of the coolant pump for

damage and/o

2. Make sure that the drive gear is not loose on the drive shaft

3. If necessary, replace the coolant pump. Refer to Disassem Remove” and Disassembly and Assembly, “Water Pump - Install”.

rerosion.

of the coolant pump.

bly and Assembly, “Water Pump -

Cylinder Head Gasket

Switch off to below normal working temperature. Remove the pressure cap for the coolant system. Start the engine an of bubbles. If bubbles are present in the coolant, combustion gases may be entering the cooling system. recommended action for the cylinder head gasket within Troubleshooting, “Coolant in Engine Oil”. Check th recommended action for checking ﬂatness of the cylinder head within Systems Operation, Testing and Adjust cap if there are no bubbles in the coolant.

theengineandallowtheenginetocool

d inspect the coolant for the presence

Check the cylinder head gasket. Refer to the

e cylinder head for ﬂatness. Refer to the

ing, “Cylinder Head - Inspect”. Fit the pressure

2. Clean t to Systems Operation, Testing and Adjusting, “Cooling System”.

he radiator and ﬂush the radiator. Refer

Water Temperature Regulator

Check operation. Refer to Systems Operation, Testing and Adjusting, “Cooling System” for the proper procedure. If ne Refer to Disassembly and Assembly, “Water Temperature Regulator - Remove and Install” for more

the water temperature regulator for correct

cessary, replace the water temperature regulator.

information.

Engine Cooling Fan

1. Make sure that the engine cooling fan is correctly

installed.

2. Make sure that the engine cooling fan is being driven correctly by the drive belt. If necessary,

ghten the drive belt or replace the drive belt.

ti Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.

i03807570

ECM Wi

llNotAcceptFactory

Passwords

Prob

One of the following items may not be recorded cor

•

Recommended Actions

1. Verify that the correct passwords were entered.

able Causes

rectly on the electronic service tool:

Passwords

Serial numbers

tal tattletale

Reason code

Check every character in each password. Remove

he electrical power from the engine for 30

t seconds and then retry.

Page 43

This document is printed from SPI². Not for RESALE

KENR6201-01 43

Troubleshooting Section

2. Verify that the electronic service tool is displaying the “Factory Pa

3. Use the electronic service tool to verify that the following inf

Engine serial number

•

Serial number for the electronic control module

•

Serial numb

•

Total tattletale

•

Reason code

•

ssword” screen.

ormation has been entered correctly:

er for the electronic service tool

i03438660

ECM Will Not Communicate with Other S yste ms or Display Modules

Probable Causes

Electrical connectors

•

Electro

•

Recomm

nic Control Module (ECM)

ended Actions

i03807610

Electronic Service Tool Will Not Communicate with ECM

Probable Causes

Conﬁguratio

•

Electrical connectors

•

Communication adapter and/or cables

•

Electrica

•

Electronic service tool and related hardware

•

Electrical power supply to the Electronic Control

•

Module (ECM)

Data link

•

Recommended Actions

Start th will not communicate with the electronic service tool, continue with this procedure. If the engine will not start, r Will Not Start”. If the engine will not crank, refer to Troubleshooting, “Engine Will Not Crank”.

e engine. If the engine starts, but the ECM

efer to Troubleshooting, “Engine Cranks but

n for the communications adapter

l power supply to the diagnostic connector

1. Connect the electronic service tool to the

stic connector. If the ECM does not

diagno communicate with the electronic service tool, refer to Troubleshooting, “Electronic Service Tool Will Not Co

2. Ensure that the following items are corre to Troubleshooting, “Electrical Connectors Inspect”.

•

3. Troubleshoot the Perkins Data Link for possible faults. Refer to Troubleshooting, “Data Link Circuit

-Te

mmunicate with ECM”.

ctly installed and undamaged. Refer

P1/J1 and P2/J2 connectors on the ECM

ng to display modules

Wiri

Wiring to other control modules

st”.

Conﬁguration for the Communications Adapter

1. Access “Preferences” under the “Utilities” menu

on the electronic service tool.

2. Verify that the correct “Communications Interface Device” is selected.

3. Verify that the correct port is selected for use by the communication adapter.

Note: The most commonly used port is “COM 1”.

4. Che

ck for any hardware that is utilizing the same port as the communications adapter. If any devices are conﬁguredtousethesameport,exit

lose the software programs for that device.

or c

Electrical Connectors

Check for correct installation of the P1/J1 and P2/J2 ECM connectors and of the diagnostic connector.

fer to Troubleshooting, “Electrical Connectors -

Re Inspect”.

Page 44

This document is printed from SPI². Not for RESALE

44 KENR6201-01 Troubleshooting Section

Communication Adapter and/or Cables

1. Make sure that the ﬁrmware and driver ﬁles are

the most current ﬁles that are available for the type of commun If the ﬁrmware and driver ﬁles do not match, the communication adapter will not communicate with the electron

2. Disconnect the communication adapter and the cables from the communication adapter to the diagnostic connector.

3. Verify that the correct cable is being used between the communication adapter and the diagnostic connector Service Tools”.

4. If the lapt operating system, restart the laptop computer in order to eliminate the possibility of a conﬂict in the softw

are.

ication adapter that is being used.

ic service tool.

the diagnostic connector. Reconnect

. Refer to Troubleshooting, “Electronic

op computer is using a Windows

Electrical Power Supply to the Diagnostic Connect

Engine Cranks but Will Not Start

Probable Causes

Diagnostic c

•

Visible faults

•

Air intake and exhaust system

•

Primary sp

•

Low pressure fuel system

•

Secondary speed/timing sensor

•

High pres

•

Glow plugs

•

Val ve la sh

•

odes

eed/timing sensor

sure fuel system

i03807671

Verify that battery vol tage is present between termina communication adapter is not receiving power, the LED display on the communication adapter will not be illu

ls A and B of the diagnostic connector. If the

minated.

Electronic Service Tool and Related Hardwa

In order to eliminate the electronic service tool and the re connect the electronic service tool to a different engine. If the same fault occurs on a different engine, check hardware in order to determine the cause of the fault.

Elec

lated hardware as the cause of the fault,

the electronic service tool and the related

trical Power Supply to the Electronic

Control Module (ECM )

k power to the ECM. Refer to Systems

Chec Operation, Testing and Adjusting, “Charging System

-Test”.

Note: If the ECM is not receiving battery voltage, the ECM will not communicate.

Low comp

•

Recomme

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

ression (cylinder pressure)

nded Actions

NOTICE

rank the engine continuously for more than

Diagnostic Codes

ne of the following methods to check for active

Use o diagnostic codes:

h Codes

Flas

•

The display on the control panel

•

The electronic service tool

•

sh Codes

Fla

Note: The following procedure is only applicable if

e machine is equipped with the appropriate warning

th lamps.

Data Link

oubleshoot the data link for possible faults. Refer

Tr to Troubleshooting, “Data Link Circuit - Test”.

eck the warning lamps on the control panel

1. Ch for ﬂash codes. Flash codes are explained in Troubleshooting, “Indicator Lamps”.

2. If any ﬂash codes are displayed, troubleshoot the codes before continuing with this procedure.

efer to Troubleshooting, “Troubleshooting with a

R Diagnostic Code”.

Page 45

This document is printed from SPI². Not for RESALE

KENR6201-01 45

Troubleshooting Section

3. Attempt to start the engine. If the engine will not start, proceed

Display on the Control Panel

Note: The following procedure is only applicable if

the machine is equipped with a display on the control panel.

1. Check the display on the control panel for active diagnostic

2. Troubleshoot any active codes before continuing with this pr “Troubleshooting with a Diagnostic Code”.

3. Attempt to start, proceed to “Visible Faults”.

Electroni

1. Connect the electronic service tool to the

2. Check for active diagnostic codes on the electronic

c Service Tool

diagnost

service t

to “Visible Faults”.

codes.

ocedure. Refer to Troubleshooting,

start the engine. If the engine will not

ic connector.

ool.

If the ambient temperature is below 0 °C (32 °F),

•

make sure that t engine oil and oil for the machine is used.

Check that the

•

Use the electronic service tool to check the

•

average cran cranking speed is less than 150 rpm, investigate the cause of the fault.

Make sure that all fuel ﬁlters are correctly

•

installed.

Drain any water from the primary fuel ﬁlter/water

•

separator.

3. Rectify any faults that are found during the visual checks.

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

he correct speciﬁcation of

battery voltage is correct.

king speed of the engine. If the

Air Intake and Exhaust System

1. Check th

eairﬁlter restriction indicator, if equipped.

3. Troubleshoot any active codes before proceeding with thi “Troubleshooting with a Diagnostic Code”.

4. Attempt start, proceed to “Visible Faults”.

Visibl

1. Visually inspect the engine for the following faults:

•

2. Che

•

s procedure. Refer to Troubleshooting,

to start the engine. If the engine will not

eFaults

Missing components

Damag

Damaged electrical cables or loose electrical cabl

Oil leaks

Fuel leaks

Check for smoke from the exhaust when the eng cranking, there may be a mechanical fault in the engine. Refer to “Low C ompression (Cylinder Pr

Check for the proper level of fuel, oil and co

Ensure that the fuel supply valve (if equipped) i

ed components

ck the following items:

ine is cranking. If smoke is seen during

essure)”.

olant.

s in the full OPEN position.

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

3. Check the air intake and exhaust systems for the

following defects:

Blockages

•

ctions

Restri

•

Damage to lines or hoses

•

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

5. Attempt to start the engine. If the engine will not start, proceed to “Primary Speed/timing Sensor”.

Primary Speed/timing Sensor

1. Disc

2. Att

3. If the engine starts, check for a fault in the circuit

4. If the engine does not start, inspect the timing ring

5. If necessary, repair the timing ring. Refer to

onnect the P401 connector from the primary

speed/timing sensor.

empt to start the engine.

the primary speed/timing sensor. Refer to

for Troubleshooting, “Engine Speed/Timing Sensor Circuit - Test”.

on the crankshaft for misalignment.

Disassembly and Assembly, “Crankshaft Timing

ing - Remove and Install”.

Page 46

This document is printed from SPI². Not for RESALE

46 KENR6201-01 Troubleshooting Section

6. Attempt to start the engine. If the engine will not start, proceed

to “Low Pressure Fuel System”.

Low Pressure Fuel System

1. If the temperature is below 0 °C (32 °F), check

for solidiﬁed fuel (wax).

2. Check for fuel supply lines that are restricted.

3. Check that t

installed.

4. Check the di Systems Operation, Testing and Adjusting, “Fuel Quality - Test”.

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

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

7. Attempt start, continue with this procedure.

8. Replace fuel ﬁlter. Refer to the Operation and Maintenance Manual, “Fuel System Primary Filter (Water Separa

9. Attempt to start the engine. If the engine will not start,

10. Check the ﬂow of fuel through the transfer pump. If the less than 250 mL per minute at 150 rpm, replace the transfer pump. Refer to Disassembly and Assem Disassembly and Assembly, “Fuel Transfer Pump

-Install”.

11. Attempt to start the engine. If the engine will not start, proceed to “Secondary Speed/timing

or”.

Sens

he low pressure fuel lines are correctly

esel fuel for contamination. Refer to

ystems Operation, Testing and

to start the engine. If the engine will not

the primary fuel ﬁlter and the secondary

tor) Element - Replace”.

continue with this procedure.

ﬂow of fuel through the transfer pump is

bly, “Fuel Transfer Pump - Remove” and

b. If the signal from the secondary speed/timing

sensor is 0 rpm, speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor Circuit - Test”.

c. If a fault is identiﬁed in the circuit for the

secondary speed/timing sensor, repair the fault and then atte engine will not start, proceed to “High Pressure Fuel System”.

d. If the signal from the secondary speed/timing

sensor is greater than 0 rpm and the engine will not sta System”.

High Press

1. Use the electronic service tool to check the

absolute f cranking at a minimum speed of 150 rpm.

2. If the abs 25 MPa (3625 psi), perform the following procedure:

a. Check that the inlet pressure at the fuel rail

pump is greater than 50 kPa (7.25 psi). If the inlet pr repeat the diagnostic process from “Low Pressure Fuel System”.

b. Check for fuel leaks in the high pressure

fuel system. Rectify any fuel leaks and then rechec rail pressure is greater than 25 M Pa (3625 psi), proceed to test step 3.

c. Use the electronic service tool to perform a

solenoid test on the fuel rail pump. Refer to Troub Tes t ” .

d. If an

of Step 2.c, attempt to start the engine. If the engine will not start, repeat the diagnostic proc

ure Fuel System

uel rail pressure while the engine is

olute fuel rail pressure is less than

essure is less than 50 kPa (7.25 psi),

k the pressure in the fuel rail. If the fuel

leshooting, “Fuel Rail Pump Solenoid -

y service has been performed as a result

ess from “Diagnostic Codes”.

investigate the secondary

mpt to start the engine. If the

rt, proceed to “High Pressure Fuel

Secondary Speed/timing S ensor

1. Connect the electronic service tool to the

diagnostic connector.

2. Check that the desired fuel rail pressure is at least 25 MPa (3625 psi) when the engine is cranking.

3. If the desired fuel rail pressure is less than 25 MPa (3625 psi), perform the following procedure:

a. Use the electronic service tool to check the

signal from the secondary speed/timing sensor

hile the engine is cranking.

e. Check the pressure relief valve in the fuel

l for leakage. If the pressure relief valve is

rai leaking, replace the valve and recheck the pressure in the fuel rail.

f. If the pressure relief valve in the fuel rail is

not leaking, check for fuel in the engine oil

stem. If fuel is suspected in the oil system,

sy take an engine oil sample for analysis. Refer to Operation and Maintenance Manual, “Engine

l Sample - Obtain”. If the analysis conﬁrms

Oi that there is fuel in the engine oil system, investigate the cause.

Page 47

This document is printed from SPI². Not for RESALE

KENR6201-01 47

Troubleshooting Section

g. If fuel is not found in the oil system, check the

electronic uni off.

h. If the leak off

in 30 seconds for a 6 cylinder engine or the leak off is greater than 25 mL (0.85 oz) in 30 seconds for a electronic unit injectors.

Note: The fa replace the pump.

i. If the leak o

seconds for a 6 cylinder engine or the leak off is less than 25 mL (0.85 oz) in 30 seconds for a 4 cylinde

3. If the absolute fuel rail pressure is greater than 25 MPa procedure:

a. Use the el

that the status of the electronic unit injectors is not “Disabled”. If the injectors are disabled but the in with the electronic service tool, proceed to test step 3.d.

b. If the electronic unit injectors are not disabled,

use the electronic service tool to perform an

r solenoid test. Refer to Troubleshooting,

injecto “Injector Solenoid Circuit - Test”.

c. If any s

of Step 3.b, attempt to start the engine. If the engine will not start, proceed to “Glow Plugs”.

d. Make sure that the latest ﬂash ﬁle for the

application is installed in the ECM. Refer to

leshooting, “Flash Programming”.

Troub

t injectors for excessive fuel leak

is greater than 38 mL (1.3 oz)

4 cylinder engine, replace the

ult is not in the fuel rail pump. Do not

ff is less than 38 mL (1.3 oz) in 30

r engine, proceed to Test Step 3.d.

(3625 psi), perform the following

ectronic service tool to make sure

jectors were not intentionally disabled

ervice has been performed as a result

i. If the engine starts normally, reconnect the

suspect ECM and returns when the suspect ECM is installed.

j. If the engine w

ECM, replace the ECM. Check that the engine starts normally. If the engine starts normally, no further test

k. Replace the ECM again and then replace the

fuel rail pu eliminated. If the engine will not start, proceed to “Glow Plugs”.

l. Check the timing of the fuel rail pump. Refer

to Systems Operation, Testing and Adjusting, “Fuel Inje

m. If the timing of the fuel rail pump required

adjustmen proceed to “Glow Plugs”.

n. If the tim

replace the fuel rail pump. If the engine will not start, proceed to “Glow Plugs”.

ing is required.

mp. Verify that the fault has been

ction Timing - Check”.

t and the engine will not start,

ing of the fuel rail pump was correct,

then verify that the fault

ill not start with the suspect

Glow Plugs

Note: Fa

when the ambient temperature is below 10 °C (50 °F).

1. Check t

2. If necessary, replace faulty glow plugs. Refer to

3. Attempt to start the engine. If the engine will not

ulty glow plugs will only affect engine starting

he operation of the glow plugs. Refer to Systems Operation, Testing and Adjusting, “Glow Plugs - Test”.

Disassembly and Assembly, “Glow Plug - Remove

stall”.

and In

, proceed to “Valve Lash”.

start

e. Contact Perkins Global Technical Support.

Note: This consultation can greatly reduce the repair

time.

f. If Perkins Global Technical Support

recommends the use of a test ECM, install a

t ECM. Refer to Troubleshooting, “Replacing

tes the ECM”.

empt to start the engine. If the engine will not

g. Att

start, install the original ECM and then proceed to Test Step 3.l.

h. If the engine starts normally , stop the engine

and then attempt to start the engine again. If

e engine will not start at the second attempt,

th proceed to Test Step 3.k.

Valve Lash

1. Check the valve lash. Refer to Systems Operation,

Testing and Adjusting, “Engine Valve Lash -

ect/Adjust”.

Insp

2. Attempt to start the engine. If the engine will not rt, proceed to “Low Compression (Cylinder

sta Pressure)”.

Compression (Cylinder Pressure)

Low

1. Perform a compression test. Refer to Systems

eration, Testing and Adjusting, “Compression

-Test”.

low compression is noted on any cylinders,

2. If

investigate the cause and rectify the cause.

Page 48

This document is printed from SPI². Not for RESALE

48 KENR6201-01 Troubleshooting Section

Possible causes of low compression are shown in the followin

Loose glow plugs

•

Faulty piston

•

Faulty pisto

•

Worn cylinder bores

•

Worn valves

•

Faulty cyli

•

Damaged cylinder head

•

3. Perform all necessary repairs.

4. Ensure tha

glist:

n rings

nder head gasket

t the repairs have eliminated the fault.

Engine Has Early Wear

Note: Th

is is not an electronic system fault.

i0343896

Make sure that the engine is maintained at the correct mainte and Maintenance Manual, “Maintenance Interval Schedule”.

nance intervals. Refer to the Operation

Dirt in Engine Oil

1. Drain the oil

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

from the crankcase and reﬁll the

ore information.

Incorrect Oil

1. Check that the engine is ﬁlled with oil of the

correct speciﬁcation. Refer to the Operation and Maintenan Recommendations”.

2. If necessa

reﬁll the engine oil system. Refer to Operation

and Maintenance Manual, “Engine Oil and Filter

- Change”

ce Manual, “Reﬁll Capacities and

ry, drain the engine oil system and

Contaminated Oil

Check an oil sample for contamination with fuel. If contamination is found, investigate the cause.

Probab

Multiple starts or cold operation

•

Incorrect maintenance intervals

•

Dirt i

•

Incorrect oil

•

Contaminated oil

•

Leak

•

Dirt in fuel

•

Low oil pressure

•

le Causes

n engine oil

s in air intake system

Recommended Actions

tiple Starts or Cold Operation

Mul

Frequent starting and stopping of the engine can

use early wear. Also, operation of the engine for

ca short periods of time in cold conditions can cause early wear.

Incorrect Maintenance Intervals

Leaks in Air Intake System

Aleaki air into the engine. Inspect the air intake system for streaks which may indicate a leakage of unﬁltered air. Inspec any leaks. Refer to Systems Operation, Testing and Adjusting, “Air Intake System” for more information.

n the air intake system may allow unﬁltered

t all of the gaskets and the connections. Repair

Dirt in Fuel

1. Remov

contamination. Install new fuel ﬁlters. Refer to the Operation and Maintenance Manual, “Fuel Syst Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element - Replace”. Determine the c

2. Check the diesel fuel for contamination. Refer to

Sys Quality - Test”.

Low

Refer to Troubleshooting, “Low Engine Oil Pressure”

r the testing procedure. Repair any identiﬁed faults.

ethefuelﬁlters. Inspect the fuel ﬁlters for

em Filter- Replace” and Operation and

ause of the contamination.

tems Operation, Testing and Adjusting, “Fuel

Oil Pressure

f the engine is not correctly maintained, early wear

I will occur.

Page 49

This document is printed from SPI². Not for RESALE

KENR6201-01 49

Troubleshooting Section

i03818598

Engine Misﬁres, Runs Rough or Is Un stab le

The probable

Note: If the fault is intermittent and the fault cannot be duplicat Low Power or Power Cutout”.

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

Probable Causes

Diagnostic codes

•

Speed dem

•

Air intake and exhaust system

•

Glow plugs

•

Valve l a

•

Fuel supply

•

root causes are listed in order below:

ed, refer to Troubleshooting, “Intermittent

fault only occurs under certain conditions,

rating temperature. Troubleshooting

and input

Air Intake and Exhaust System

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

2. Ensure that th

3. Check the air intake and exhaust systems for the

following de

Blockages

•

Restrictions

•

Damage to li

•

4. If the repairs do not eliminate the fault proceed to

“Glow Plug

eairﬁlter is clean and serviceable.

fects:

nes or hoses

s”.

Glow Plugs

1. Check for proper operation of the glow plugs.

Refer to Systems Operation, Testing and Adjustin

2. If the repairs do not eliminate the fault refer to

“Valve L

g, “Glow Plugs - Test”.

ash”.

Valve Lash

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

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

usting, “Engine Valve Lash - Inspect and

Fuel rail pump

•

Low co

•

Individual malfunctioning cylinder

•

Electronic unit injectors

•

mpression (cylinder pressure)

Recommended Actions

nostic Codes

Diag

Check for active diagnostic codes on the electronic

vice tool. Troubleshoot any active codes before

ser continuing with this procedure.

ed Demand Input

Spe

1. Use the electronic service tool and observe the

gnal for the Speed Demand Input.

2. If the signal is erratic, refer to Troubleshooting, peed Control (Analog) - Test” or Troubleshooting,

“S “Speed Control (Digital) - Test”.

f the repairs do not eliminate the fault proceed to

3.I

“Air Intake and Exhaust System”.

2. If the r

Fuel S

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

2. Ensure that the fuel supply valve (if equipped) is

3. If the temperature is below 0 °C (32 °F), check

4. Check the primary ﬁlter/water separator for water

5. Check for fuel supply lines that are restricted.

6. Check that the low pressure fuel lines are tight

7. Check the fuel ﬁlters.

8. Ch

epair does not eliminate the fault proceed to

“Fuel Supply”.

upply

gauge

in th

for s

in t

and secured properly.

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

may be faulty.

e full OPEN position.

olidiﬁed fuel (wax).

he fuel.

eck the diesel fuel for contamination. Refer to

Page 50

This document is printed from SPI². Not for RESALE

50 KENR6201-01 Troubleshooting Section

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

Operation, Tes Tes t ” .

10. Ensure that th

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

11. Check the fuel pressure. Refer to Systems

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

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

“Fuel Rail P

ting and Adjusting, “Air in Fuel -

e fuel system has been primed.

est”.

ump”.

Fuel Rail Pump

Note: The fuel rail pump that is installed by the

factory is a nonserviceable item. If any mechanical fault or an pump then the fuel rail pump must be replaced.

1. Use the el

correct screen display. Refer to Troubleshooting, “Troubleshooting with a Diagnostic Code”.

2. If the fault is not eliminated, refer to “Low

Compression (Cylinder Pressure)”.

y electrical fault occurs within the fuel rail

ectronic service tool to select the

Low Compression (Cylinder Pressure)

1. Perfor

m a compression test. Refer to Systems

Operation, Testing and Adjusting, “Compression

-Test”.

Individual M alfunctioning Cylinders

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

2. Rectify an

3. If all cylinders have been checked and no

faults wer Injectors”.

Electron

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

electro a time. Note if there is any reduction in engine speed. If a reduction in engine speed is not noted, the isol under normal conditions. If the isolation of a particular cylinder results in a reduction of engine speed t that the electronic unit injector is operating below normal performance.

ic Unit Injectors

nic service tool to isolate one cylinder at

ated electronic unit injector is not operating

hat is less than normal, this may indicate

there is any reduction in engine

If the isolation of a particular cylinder

elow normal performance. Investigate

der that is operating below normal

y faults.

e detected proceed to “Electronic Unit

2. If low compression is noted on any cylinders,

investigate the cause and rectify the cause.

Possible causes of low compression are shown in the following list:

Loose glow plugs

•

ty piston

Faul

•

Faulty piston rings

•

Worn cylinder bores

•

nvalves

Wor

•

Faulty cylinder head gasket

•

Damaged cylinder head

•

rform all necessary repairs.

3. Pe

4. Ensure that the repairs have eliminated the faults.

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

“Individual Malfunctioning Cylinders”.

2. Remove the electronic unit injector from the suspect cylinder. Refer to Disassembly and Assem

3. Install a new electronic unit injector. Refer to Disas Injector - Install”.

4. Repe remove the replacement electronic unit injector and install the original electronic unit injector. Refe Unit Injector - R emove” and Disassembly and Assembly, “Electronic Unit Injector - Install”.

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

bly, “Electronic Unit Injector - Remove”.

sembly and Assembly, “Electronic Unit

at the test in 1. If the fault is still apparent,

r to Disassembly and Assembly, “Electronic

i03439006

Engine Oil in Cooling System

Note: This is not an electronic system fault.

Page 51

This document is printed from SPI². Not for RESALE

KENR6201-01 51

Troubleshooting Section

Probable Causes

Engine oil cooler

•

Cylinder head gasket

•

Cylinder head

•

Cylinder block

•

Recommended Actions

Engine Oil Cooler

1. Drain the coolant from the engine and the radiator.

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

2. Check for leaks in the oil cooler assembly. Refer to Systems Operation, Testing and Adjusting, “Cooling System” for the correct procedure. If a leak is found, install a new oil cooler. Refer to Disassembly and Assembly, “Engine Oil Cooler

- Remove” and Disassembly and Assembly, “Engine Oil Cooler - Install” for the correct procedure.

Cylinder Head Gasket

1. Remove the cylinder head. Refer to Disassembly

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

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

Cylinder Block

lock. If signs of leakage are found,

the correct procedure.

Assembly after Repair

1. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.

2. Replenish the engine with clean engine oil to the correct level. Refer to the Operation and Maintenan Change” for more information.

3. Fill the co Maintenance Manual, “Cooling System Coolant (ELC) - Change”.

ce Manual, “Engine Oil and Filter -

oling system. Refer to the Operation and

i03439063

Engine Vibration

Note: This is not an electronic system fault.

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

Probable Causes

3. To ﬁt a new cylinder head gasket, refer to

Disassembly and Assembly, “Cylinder Head Install” for the correct procedure.

4. If there was no obvious signs of a faulty head gasket proceed to “Cylinder Head”.

Vibration damper

•

Engine supports

•

Low compression (cylinder pressure)

•

Individual malfunctioning cylinder

•

Cylinder Head

Electronic unit injectors

•

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

2. Check the mating face of the cylinder head for faults and signs of leakage. If a fault is found, replace the cylinder head. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation, Testing and Adjusting, “Cylinder Head - Inspect” for the correct procedure.

3. If the cylinder head is ﬂat and if the cylinder head does not have any faults, refer to “Cylinder Block”.

Recommended Actions

Vibration Damper

Check the vibration damper for damage. Install a new vibration damper, if necessary. Inspect the mounting bolts for damage and/or for wear. Replace any damaged bolts. Refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove” and Disassembly and Assembly, “Vibration Damper and Pulley - Install”.

Page 52

This document is printed from SPI². Not for RESALE

52 KENR6201-01 Troubleshooting Section

Ensure that the repairs have eliminated the fault. If the vibratio Supports”.

Engine Suppor

1. Check for any of the following conditions:

Loose engine supports

•

Loose mount

•

brackets

Loose bolts

•

Omitted bolts

•

2. Make all necessary repairs. Ensure that the repairs have eliminated the fault. If the vibration is still pr (Cylinder Pressure)”.

Low Compr

1. Perform a compression test. Refer to Systems

Operati

-Test”.

2. If low co investigate the cause and rectify the fault.

Possib in the following list:

Loose g

•

Faulty piston

•

Faulty piston rings

•

Worn c

•

Worn valves

•

Faulty cylinder head gasket

•

Dama

•

n is still present proceed to “Engine

ing brackets or broken mounting

esent proceed to “Low Compression

ession (Cylinder Pressure)

on, Testing and Adjusting, “Compression

mpression is noted on any cylinders,

le causes of low compression are shown

low plugs

ylinder bores

ged cylinder head

Malfunctioning Individual C ylinder

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

2. If all cyli faults were detected proceed to “Electronic Unit Injectors”.

there is any reduction in engine

If the isolation of a particular cylinder

elow normal performance. Investigate

der that is operating below normal

nders have been checked and no

Electronic Unit Injectors

1. With the e

2. Remove the electronic unit injector from the suspec Assembly, “Electronic Unit Injector - Remove”.

3. Insta Disassembly and Assembly, “Electronic Unit Injector - Install”.

4. Repeat the test in 1. If the fault is still apparent, remove the replacement electronic unit injector and i Refer to Disassembly and Assembly, “Electronic Unit Injector - R emove” and Disassembly and Asse

ngine speed at a fast idle, use the

f a reduction in engine speed is not noted,

lar cylinder results in a reduction of engine

performance.

t cylinder. Refer to Disassembly and

ll a new electronic unit injector. Refer to

nstall the original electronic unit injector.

mbly, “Electronic Unit Injector - Install”.

3. Perform all necessary repairs.

4. Ensure that the repairs have eliminated the fault.

he repair does not eliminate the fault refer to

5. If t “Malfunctioning Individual Cylinder”.

Engine Will Not Crank

Probable Causes

Power generator

•

Battery cables and/or batteries

•

Starting motor solenoid or starting circuit

•

i03808792

Page 53

This document is printed from SPI². Not for RESALE

KENR6201-01 53

Troubleshooting Section

Starting motor and/or ﬂywheel ring gear

•

Electrical power supply

•

Internal engi

•

Control system

•

ne fault

Recommended Repairs

Power Generator

Make sure th If the power generator does not rotate, refer to the documentation that is supplied by the OEM.

Battery Cables and/or Batteries

1. Inspect th

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

2. Inspect the batteries.

at the power generator is free to rotate.

e main power switch, battery posts,

e battery cables and clean the battery

Internal Engine Fault

1. Remove the glow plugs. Refer to Disassembly

and Assembly, “Glow Plugs - Remove and Install”.

2. Attempt to rotate the crankshaft through 360 degrees in both direction. If the crankshaft rotates correctly bu glow plug, investigate the cause of the ﬂuidinthe cylinder.

3. If the crankshaft rotates correctly and no ﬂuid is expelled, install the glow plugs. Refer to Disassembl Remove and Install”.

4. If the engi the engine. Refer to Disassembly and Assembly.

5. Inspect th conditions:

Seizure

•

Broken components

•

Bent components

•

t ﬂuid is expelled from the hole for the

y and Assembly, “Glow Plugs -

ne does not rotate in Step 2, disassemble

e internal components for the following

a. Charge t

b. Load test the batteries. Refer to Systems

Operati Tes t ” .

Starti

ng Motor Solenoid or Starting

he batteries.

on, Testing and Adjusting, “Battery -

Circuit

1. Te st t

2. Check the wiring to the starting motor solenoid.

Star

1. Test the operation of the starting motor. Check the

2. Inspect the pinion on the starting motor and the

he operation of the starting motor solenoid. Refer to Systems Operation, Testing and Adjusting, “Electric Starting System - Test”.

ting Motor and/or Flywheel Ring Gear

ng for the starting motor. Refer to Systems

wiri Operation, Testing and Adjusting, “Electric Starting System - Test”.

ﬂywheel ring gear for damage.

Electrical Power Supply

there is no electrical power supply, investigate the

If cause and rectify any defects. Refer to Systems Operation, Testing and Adjusting, “Charging System

est”.

-T

Control

Check that power is being provided from the control system

Note: If power is not reaching the solenoid on the starti

System

to the solenoid on the starting motor.

ng motor, the engine will not crank.

i03808909

Excessive Black Smoke

Probable Causes

Diagnostic codes

•

ECM software

•

Air intake system or exhaust system

•

Val ve la sh

•

Turbocharger

•

Low compression (cylinder pressure)

•

Electronic unit injectors

•

Individual malfunctioning cylinder

•

Page 54

This document is printed from SPI². Not for RESALE

54 KENR6201-01 Troubleshooting Section

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.

ECM Software

1. Connect the electronic service tool to the

diagnostic connector and check for the following conditions

Check for the correct engine serial number

•

Check for the correct arrangement number

•

Check for t

•

2. Use the electronic service tool to verify any active diagnost

3. If diagnostic codes are present, the Electronic Control M the correct information.

4. If the re to “Air Intake System or Exhaust System”.

Air Inta

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

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

3. Check

the following defects:

Block

•

Restrictions

•

Damage to the air intake and exhaust lines and

•

hoses

4. Make all necessary repairs to the engine.

he fault has not been eliminated, proceed to

5. If t “Valve Lash”.

ve Lash

Val

Ensure that the valve lash is correct. Reset the

lve lash if it is not correct. Refer to Systems

va Operation, Testing and Adjusting, “Engine Valve Lash

- Inspect/Adjust”.

he correct software

ic codes.

odule (ECM) must be programmed with

pairs have not eliminated the fault proceed

ke System or Exhaust System

the air intake and the exhaust system for

ages

Turbocharger

Note: The turbocharger that is installed on this

engine is a nonserviceable item. If any mechanical fault exists,

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

2. Check that the oil drain for the turbocharger is not blocked or r

3. Check that the compressor housing for the turbocharg

4. Check that the turbine housing for the turbocharger is free of d

5. Check that the turbine blades rotate freely in the turbochar

6. Ensure that the wastegate on the turbocharger is adjusted Testing and Adjusting, “Wastegate - Inspect”. If the wastegate actuator is faulty, replace the turbocha “Turbocharger - Remove” and Disassembly and Assembly, “Turbocharger - Install”.

7. If necessary, replace the turbocharger. Refer to Disassembly and Assembly, “Turbocharger

- Remove “Turbocharger - Install”.

8. Check t

9. If the repairs have not eliminated the fault proceed

to “Lo

then the turbocharger must be replaced.

estricted.

er is free of dirt, debris and damage.

irt, debris and damage.

ger.

correctly. Refer to Systems Operation,

rger. Refer to Disassembly and Assembly,

” and Disassembly and Assembly,

hat the repairs have eliminated the fault.

w Compression (Cylinder Pressure)”.

Low Compression (Cylinder Pressure)

1. Perform a compression test. Refer to Systems

Operation, Testing and Adjusting, “Compression

t”.

-Tes

2. If low compression is noted on any cylinders,

stigate the cause and rectify the cause.

inve

Possible causes of low compression are shown

he following list:

in t

Loose glow plugs

•

Faulty piston

•

ulty piston rings

•

Worn cylinder bores

•

If the repair does not eliminate the fault proceed to “Turbocharger”.

Worn valves

•

aulty cylinder head gasket

•

Page 55

This document is printed from SPI². Not for RESALE

KENR6201-01 55

Troubleshooting Section

Damaged cylinder head

•

3. Perform all necessary repairs.

4. Ensure that th

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

“Electronic

erepairshaveeliminatedthefault.

Unit Injectors”.

Electronic Unit Injectors

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

electronic service tool to isolate one cylinder at atime.Note speed. If a reduction in engine speed is not noted, the isolated electronic unit injector is not operating under norm particular cylinder results in a reduction of engine speed that is less than normal, this may indicate that the el normal performance.

2. Remove th suspect cylinder. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”.

3. Install a new electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injecto

4. Repeat the test in 1. If the fault is still apparent, remove and install the original electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit In Assembly, “Electronic Unit Injector - Install”.

5. If the

fault is not eliminated, proceed to “Individual

Malfunctioning Cylinder”.

if there is any reduction in engine

al conditions. If the isolation of a

ectronic unit injector is operating below

e electronic unit injector from the

r-Install”.

the replacement electronic unit injector

jector - Remove” and Disassembly and

i03443800

Excessive Engine Oil Consumption

Probable Causes

Misreading o

•

Oil leaks

•

Engine crankcase breather

•

Oil level

•

Air intake and exhaust system

•

Turbocharger

•

Low compr

•

Recommen

Misreading Oil Level

1. Accurately measure the consumption of oil and

fuel over a period of 50 engine hours.

2. If the oil consumption is greater than 0.2% of the fuel consumption, use the following procedure in orde consumption.

Oil Le

1. Check for evidence of oil leaks on the engine.

aks

il level

ession (cylinder pressure)

ded Actions

r to investigate the cause of the high oil

idual Malfunctioning Cylinder

Indiv

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

tronic service tool to isolate one cylinder at

elec a time. Note if there is any reduction in engine speed. If a reduction in engine speed is not noted,

solated cylinder is not operating under normal

the i conditions. If the isolation of a particular cylinder results in a reduction of engine speed that is less

n normal, this may indicate that the cylinder is

tha operating below normal performance. Investigate the cause of the fault on any cylinder that is

operating. Investigate the cause of the fault

not on any cylinder that is operating below normal performance.

2. If all cylinders have been checked and no faults were detected, refer to the Troubleshooting Guide

r the application.

2. Rectify any oil leaks from the engine.

3. Chec

4. If no

Eng

1. Check the engine crankcase breather for blockage

2. Check for excessive oil from the outlet of the

3. Repair all defects. Verify that the repair has

4. If no faults are found, refer to “Oil Level”.

k for evidence of oil in the coolant. Refer to

Troubleshooting, “Engine Oil in Cooling System”.

oil leaks are identiﬁed, refer to “Engine

Crankcase Breather”.

ine Crankcase Breather

estrictions.

or r

eather.

iminated the fault.

Page 56

This document is printed from SPI². Not for RESALE

56 KENR6201-01 Troubleshooting Section

Oil Level

1. Check the oil level in the engine.

2. If the oil leve

of the oil with coolant. Refer to Troubleshooting, “Coolant in Engine Oil”.

3. If no contamination is identiﬁed, remove any excess oil.

4. If the oil level is satisfactory, refer to “Air Intake and Exhaust System”.

l is high, check for contamination

Air Intake and Exhaust System

1. Check the a

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

3. Check the air intake and the exhaust system for

the following defects:

Blockages

•

Restric

•

Damage to the air intake and exhaust lines and

•

hoses

ir ﬁlter restriction indicator, if equipped.

tions

Low Compression (cylinder pressure)

1. Perform a compression test. Refer to Systems

Operation, Testing and Adjusting, “Compression

-Test”.

2. If low compression is noted on any cylinders, investigate

Possible causes of low compression are shown in the follo

Loose glow plugs

•

Faulty piston

•

Worn pisto

•

Worn cylinder bores

•

Worn valves

•

Faulty cy

•

Damaged cylinder head

•

3. Perform all necessary repairs.

4. Ensure t

the cause and rectify the cause.

wing list:

nrings

linder head gasket

hat the repairs have eliminated the faults.

4. Make all necessary repairs to the engine.

5. Ensure that the repairs have eliminated the

diagnostic code.

6. If no faults are found, refer to “Turbocharger”.

Turbo

Note: The turbocharger that is installed on this

engin fault exists, then the turbocharger must be replaced.

1. Chec

2. Chec

3. If n

4. Check that the repairs have eliminated the faults.

charger

e is a nonserviceable item. If any mechanical

k that the oil drain for the turbocharger is not

blocked or restricted.

k the turbocharger for evidence of internal

oil leaks.

ecessary, replace the turbocharger. Refer

to Disassembly and Assembly, “Turbocharger

- Remove” and Disassembly and Assembly, rbocharger - Install”.

“Tu

5. If the fault is not eliminated, refer to the Trouble

shooting Guide for the application.

i03808930

Excessive Fuel Consu mp tio n

Probable Causes

Fuel quality

•

Quality of oil

•

Low engine temperature

•

Air intake and exhaust system

•

Reduced pressure of intake air

•

Excessive valve lash

•

Failure of the primary speed/timing sensor

•

5. If the repairs have not eliminated the fault proceed to “Low Compression (cylinder pressure)”.

Page 57

This document is printed from SPI². Not for RESALE

KENR6201-01 57

Troubleshooting Section

Recommended Ac

tions

Fuel Quality

1. The quality of the fuel that is used in the engine

will affect the rate of fuel consumption. Refer to “General Fuel Maintenance Manual, “Reﬁll Capacities”.

2. If the fuel is the fuel system and replace the fuel ﬁlters. Reﬁll the fuel system with fuel of an acceptable quality. Refer to the and Maintenance Manual.

3. If the fuel i “Quality of Oil”.

Quality of

1. The nominal viscosity of the lubricating oil that

is used in consumption. The viscosity of lubricating oil is deﬁned by the SAE grade of the lubricating oil. The grade for the ambient conditions. Lubricating oil that is intended for use in high ambient temperatures will hav consumption in cold ambient temperatures. Refer to “Engine Oil” in the Operation and Maintenance Manual,

2. The actual viscosity of the lubricating oil that is used in service life of the oil. Lubricating oil that is heavily contaminated will have a negative effect upon the rate o

3. If the oil is not of an acceptable quality or if the oil ha system and replace the oil ﬁlters. Reﬁll the oil system with oil of an acceptable quality. Refer to th Maintenance Manual.

4. If th Engine Temperature”.

Low

1. The operating temperature of the engine will affect

the engine below the correct temperature will increase fuel consumption. Failure of the water temperature re the correct temperature.

e a negative effect upon the rate of fuel

f fuel consumption.

s exceeded the service life, drain the oil

e applicable sections in the Operation and

e oil is of an acceptable quality, refer to “Low

Engine Temperature

rate of fuel consumption. Operation of the

gulator can prevent the engine from operating at

Information” in the Operation and

not of an acceptable quality, drain

applicable sections in the Operation

s of an acceptable quality, refer to

Oil

the engine will affect the rate of fuel

of the lubricating oil must be correct

“Reﬁll Capacities”.

the engine will change throughout the

2. If the engine operating temperature is low, check the operation o the water temperature regulator does not operate correctly, a new water temperature regulator must be installed. “Water Temperature Regulator - Remove and Install”.

f the water temperature regulator. If

Refer to Disassembly and Assembly,

Air Inlet and Exhaust System

Leakage of g the air intake or the exhaust system can reduce the ﬂow of combustion gas through the engine. A change in th adversely affects combustion efﬁciency and the rate of fuel consumption.

1. Check the air intake system for leakage or restrictions. Refer to Systems Operation, Testing and Adjust

2. Check the exhaust system for leakage or restrict and Adjusting, “Air Inlet and Exhaust System”.

3. Repair a eliminated the fault.

Reduced

1. If the pressure of the intake air at the intake

manifo of the engine will need to be higher or more fuel must be injected in order to produce the same power. fuel consumption.

2. Check compressor to the intake manifold for leaks. If necessary, repair any leaks.

3. Check for the correct operation of the wastegate in the turbocharger. Refer to Systems Operation, Te s t Te s t”.

4. If th replace the turbocharger. Refer to Disassembly and Assembly, “Turbocharger - Remove” and

assembly and Assembly, “Turbocharger -

Dis Install”.

essive Valve Lash

Exc

Excessive valve lash will cause a change in the

ming of the opening and closing of the inlet and

ti exhaust valves. Excessive valve lash can cause a reduction of the ﬂow of combustion air into the

gine. Reduced ﬂow of combustion air will increase

en the fuel consumption rate.

as or an increased restriction in either

e ﬂow of combustion air into the engine

ing, “Air Inlet and Exhaust System”.

ions. Refer to Systems Operation, Testing

ll defects. Verify that the repair has

Pressure of Intake Air

ld is lower than normal, either the speed

Either of these conditions will increase the

the pipe from the outlet of the turbocharger

ing and Adjusting, “Turbocharger Wastegate -

e turbocharger is suspected as being faulty,

Page 58

This document is printed from SPI². Not for RESALE

58 KENR6201-01 Troubleshooting Section

Refer to the Troubleshooting Guide, “Excessive Valve Lash”.

Failure of the Primary Speed/Timing Sensor

If the primary speed/timing sensor fails, the engine will continu secondary speed/timing sensor on the fuel rail pump. The secondary speed/timing sensor is less precise tha differences between the secondary speed/timing sensor and the primary speed/timing sensor may cause an inc

1. Use the electronic service tool to check for active dia speed/timing sensor.

2. If necessa sensor. Refer to Disassembly and Assembly, “Speed/Timing Sensor - Remove and Install”.

etooperateusingthesignalfromthe

n the primary speed/timing sensor. Timing

rease in fuel consumption.

gnostic codes that relate to the primary

ry, replace the primary speed/timing

i03809014

Excessive Valve Lash

Rocker arms

•

Valve bridges

•

Pushrods

•

Valve lifters

•

Camshaft

•

Valve s tems

•

Rocker shafts

•

2. Check the components for the following conditions: abnormal wear, excessive wear, straightness, and cleanl replacement.

Note: If th must also be used.

Valve Las

Adjust the valve lash of the engine. Refer to Systems Operati

- Inspect/Adjust” for the correct procedure.

iness. If necessary, use new parts for

e camshaft is replaced, new valve lifters

on, Testing and Adjusting, “Engine Valve Lash

Note: This is not an electronic system fault.

Probable Causes

Lubrication

•

Valve train components

•

Valve l ash

•

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. Crank the engine and 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.

Note: Do not run the engine without the valve mechanism cover.

i03447260

Excessive White Smoke

Note: Some white smoke may be present during

cold start-up conditions when the engine is operating normally. If the white smoke persists, there may be a fault.

Probable Causes

Coolant temperature sensor circuit

•

Low coolant temperature

•

Glow plugs

•

Fuel quality

•

Val ve la sh

•

Low compression (cylinder pressure)

•

Individual malfunctioning cylinder

•

Recommended Actions

Valve Train Components

1. Inspect the following components of the valve

train:

Coolant Temperature Sensor Circuit

1. Connect the electronic service tool to the

diagnostic connector.

Page 59

This document is printed from SPI². Not for RESALE

KENR6201-01 59

Troubleshooting Section

2. Monitor the display screen on the electronic service tool in diagnostic codes for the coolant temperature. Refer to Troubleshooting, “Engine Temperature Sensor Open or

3. If the fault has not been eliminated, proceed to “Low Coolant

order to verify the presence of active

Short Circuit - Test”.

Temperature”.

Low Coolant Temperature

Check that the water temperature regulator is operating correctly. Refer to Systems Operation, Tes t i ng a n d

-Test”.

If the wate correctly, refer to “Glow Plugs”.

Adjusting, “Water T emperature Regulator

r temperature regulator is operating

Glow Plugs

1. Check for proper operation of the glow plugs.

Refer to S Adjusting, “Glow Plugs - Test”.

2. If the re “Fuel Quality”.

Fuel Qua

1. Check the diesel fuel for quality. Refer to Systems

Operat Tes t ” .

Note: D cause white smoke.

ystems Operation, Testing and

pairs do not eliminate the fault refer to

lity

ion, Testing and Adjusting, “Fuel Quality -

iesel fuel with a low cetane value is likely to

Faulty piston

•

Faulty piston rings

•

Worn cylinder

•

Worn valves

•

Faulty cylinder head gasket

•

Damaged cyl

•

3. Perform all necessary repairs.

4. Ensure that the repairs have eliminated the faults.

5. If the repa

“Individual Malfunctioning Cylinder”.

Individua

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

electron a time. Note if there is any reduction in engine speed. If a reduction in engine speed is not noted, the isol conditions. If the isolation of a particular cylinder results in a reduction of engine speed that is less than nor operating below normal performance. Investigate the cause of the fault on any cylinder that is not ope on any cylinder that is operating below normal performance.

2. Rectify any faults.

l Malfunctioning Cylinder

icservicetooltoisolateonecylinderat

ated cylinder is not operating under normal

mal, this may indicate that the cylinder is

rating. Investigate the cause of the fault

bores

inder head

ir does not eliminate the fault refer to

2. If the

repair does not eliminate the fault refer to

“Valve Lash”.

i02414540

Intake Air Temperature Is Too

Valve

1. Ensure that the valve lash is correct. Refer

2. If th

Low

1. Perform a compression test. Refer to Systems

2. If

Lash

stems Operation, Testing and Adjusting,

to Sy “Engine Valve Lash - Inspect/Adjust”.

e repair does not eliminate the fault proceed to

“Low Compression (cylinder pressure)”.

Compression (cylinder pressure)

ration, Testing and Adjusting, “Compression

Ope

-Test”.

low compression is noted on any cylinders,

investigate the cause and rectify the cause.

ssible causes of low compression are shown

Po in the following list:

oose glow plugs

•

High

Probable Causes

High ambient air temperature

•

Intake air restriction and/or high altitude

•

Intake air from a heated area

•

Intake manifold air temperature sensor and/or

•

circuit

Insufﬁcient ambient air ﬂow over the engine

•

Reduced ambient air ﬂow through the air charge

•

cooler

Page 60

This document is printed from SPI². Not for RESALE

60 KENR6201-01 Troubleshooting Section

Reduced ﬂow of intake air through the air charge

•

cooler

Recommended A

ctions

High Ambient Air Temperature

1. Determine if the ambient air temperature is within

the design speciﬁcations for the cooling system and the air ch

2. When the ambient temperature exceeds the capability cooler, operate the engine at a reduced load or operate the engine at a reduced speed.

3. When possible, modify the cooling system and the air charge cooler in order to make the system suitable f

arge cooler.

of the cooling system or the air charge

or local conditions.

Intake Air Restriction and/or High Altitude

Low air pressure at the air intake for the turbocharger canbecausedbyarestrictionintheairintakeora high alti is low, the turbocharger (if equipped) works harder in order to achieve the desired intake manifold pressur

Measure the intake manifold pressure while the engine i refer to the Perkins Technical Marketing Information for the engine.

tude. When the pressure of the intake air

e. This increases intake air temperature.

s operating under load. For speciﬁcdata,

Intake Manifold Air Temperature Sensor and/or the Circ

1. Allow the intake manifold air temperature sensor

to cool and rem for the intake air temperature. If the sensor is operating correctly, the reading and the ambient temperature

2. If the readings are approximately equal, reinstall the sensor.

3. If the reading is not correct, replace the sensor withasenso the fault is rectiﬁed.

Insufﬁcie

nt Ambient Air Flow over the

uit

ove the sensor. Check the reading

are approximately equal.

r that is known to be good. Verify that

Engine

1. If equippe

and the drive belt.

2. If equipp correctly.

Reduced

d, check the condition of the cooling fan

ed, check that the cooling fan is operating

Ambient Air Flow th rough the

Air Charge Cooler

1. Check th

charge cooler is not obstructed.

2. Inspec and/or bent ﬁns or damaged ﬁns.

at the ambient air ﬂow through the air

t the air charge cooler for contamination

Intake Air Restriction

1. Check

2. Repla

High

Make sure that the settings for the engine are correct for t

for blocked air ﬁlters. Check for obstructions

in the air intake.

ce the air ﬁlters or remove the obstruction

from the air intake.

Altitude

he altitude.

Intake Air f rom a Heated Area

1. Ensure that the air inlet system is not receiving

air from a heated area.

2. If necessary, relocate the air supply to the intake manifold to the outside of the engine enclosure.

3. Check for air leaks in the pipe between the air inlet and the inlet to the turbocharger compressor.

3. If nece

4. If necessary, carefully straighten any bent ﬁns on

the ai

ssary, clean the air charge cooler.

r charge cooler.

Reduced Flow of Intake Air through the Air Ch

1. Check for contamination in the air pipe that

2. If a thick oil ﬁ lm is found in the air pipe, inspect the

arge Cooler

ects the turbocharger to the air charge cooler.

conn

a. If dirt is found in the air pipe from the

ocharger to the air charge cooler, check

turb all of the air inlet pipes upstream of the turbocharger for leaks.

b. Clean all contaminated air inlet pipes or replace

all contaminated air inlet pipes.

c. Service the air cleaner and replace the air

cleaner element.

turbocharger compressor housing. Examine both

e inlet to the turbocharger compressor housing

th and the outlet from the turbocharger compressor for oil.

Page 61

This document is printed from SPI². Not for RESALE

KENR6201-01 61

Troubleshooting Section

a. If oil is found in the inlet to the turbocharger

compressor hou engine crankcase breather.

b. If oil is found

compressor housing but oil is not found in the inlet to the compressor housing, the oil originates f bearings.

sing, the oil originates from the

in the outlet from the turbocharger

rom the seals for the turbocharger

i03809049

Intermittent Engine Shutdown

Note: Use this procedure only if the engine shuts

down completely and the engine must be restarted.

Probable Causes

Diagnostic codes

•

Electrical connectors

•

Fuel supply

•

Recommended Actions

Diagnostic Codes

3. Use the electronic service tool to check for

the following l “Personality Module mismatch”. If this diagnostic code is logged, proceed to Troubleshooting, “Electrical C

4. Inspect the battery wires from the ECM to the battery comp Diagram. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Ref Keyswitch Circuit and Battery Supply Circuit Test” for more information.

5. Repair any faults and ensure that the symptom has been cleared. If the symptom is still present, refer to “F

ogged diagnostic code: 253-2

onnectors - Inspect”.

artment. Refer to the Engine Wiring

er to Troubleshooting, “Ignition

uel Supply”.

Fuel Supply

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

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

gauge may be faulty.

2. Ensure that the fuel supply valve (if equipped) is

in the full OPEN position.

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

Electrical Connectors

1. Check for correct installation of ECM connectors

at the following locations:

P1 ECM connector

•

P2 ECM connector

•

P100 Engine coolant temperature sensor

•

connector

P201 Engine oil pressure sensor connector

•

P401 Primary speed/timing sensor connector

•

P402 Secondary speed/timing sensor connector

•

P532 Fuel injection pump solenoid connector

•

2. Refer to Troubleshooting, “Electrical Connectors

- Inspect”.

3. If the temperature is below 0 °C (32 °F), check

for solidiﬁed fuel (wax).

4. Check the primary ﬁlter/water separator for water

in the fuel.

5. Check for fuel supply lines that are restricted.

6. Check that the low pressure fuel lines are tight

and secured properly.

7. Check the fuel ﬁlters.

8. Check the diesel fuel for contamination. Refer to

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

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

Operation, Testing and Adjusting, “Air in Fuel Te s t”.

10. Ensure that the fuel system has been primed.

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

11. Check the fuel pressure. Refer to Systems

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

Page 62

This document is printed from SPI². Not for RESALE

62 KENR6201-01 Troubleshooting Section

i03809069

Intermittent Low Pow er or Power Cutout

Note: Use thi

shut down completely.

Probable Causes

Diagnostic

•

Electrical connectors

•

ECM connection

•

Fuel suppl

•

Intake manifold pressure

•

Recommended Actions

Do not crank the engine continuously for more than 30 secon minutes before cranking the engine again.

s procedure only if the engine does not

codes

NOTICE

ds. Allow the starting motor to cool for two

3. V erify the correct pin positions for the power

connections an ECM.

4. If a fault is su

ground connections refer to Troubleshooting, “Ignition Keyswitch Circuit and Battery Supply Circuit - Tes

5. Verify that the ECM connections for the power and

ground conn connected.

6. Repair any f

been eliminated.

7. If the repa

to “Fuel Supply”.

Fuel Suppl

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

gauge may

2. Ensure that the fuel supply valve (if equipped) is

in the fu

3. If the temperature is below 0 °C (32 °F), check

for soli

ll OPEN position.

diﬁed fuel (wax).

d the ground connections for the

spected with the ECM power and

t”.

ections at the fuel pump are correctly

aults and ensure that the faults have

irs do not eliminate the faults, proceed

be faulty.

Diagno

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

Elect

1. Refer to Troubleshooting, “Electrical Connectors

2. Repair the electrical connectors or replace the

3. Ensure that all the connector seals are in place

4. Ens

stic Codes

e tool. Troubleshoot any active codes before

rical Connectors

pect”.

-Ins

trical connectors.

elec

that the connectors have been correctly

and installed.

ure that the repairs have eliminated the fault. If the fault has not been eliminated proceed to “ECM Connection”.

ECM Connection

eck that the P2/J2 connector is correctly

1. Ch connected.

4. Check the primary ﬁlter/water separator for water in the f

5. Check for fuel supply lines that are restricted.

6. Check that the low pressure fuel lines are tight

and secured properly.

7. Check the fuel ﬁlters.

8. Check

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

9. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Te s t

10. Ensure that the fuel system has been primed. Ref Adjusting, “Fuel System - Prime”.

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

12. If the repair does not eliminate the fault refer to “Intake Manifold Pressure”.

uel.

the diesel fuel for contamination. Refer to

”.

er to Systems Operation, Testing and

ck the fuel pressure. Refer to Systems

heck that the P1/J1 connector is correctly

2.C

connected.

Page 63

This document is printed from SPI². Not for RESALE

KENR6201-01 63

Troubleshooting Section

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 int

should read 0 kPa (0 Psi).

4. Use the elec following logged diagnostic codes:

1785-3 Inta

•

high

1785-4 Int

•

low

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

ake manifold pressure. The pressure

tronic service tool to check for the

ke Manifold Pressure Sensor voltage

ake Manifold Pressure Sensor voltage

f these diagnostic codes are logged,

i03809089

Low Eng ine Oil Pressure

NOTICE Do not operate the engine with low oil pressure. Engine damage will result. If measured oil pressure is

iscontinue engine operation until the problem is

low, d corrected.

Prob

•

able Causes

Engine oil level

Oil speciﬁcation

ine oil pressure gauge

Eng

2. If the fault is still apparent, proceed to “Oil Speciﬁcation”

Oil Speciﬁcation

1. Make sure that engine oil of the correct

speciﬁcation is used. Refer to the Operation and Maintena Recommendations”.

2. If necessar system with engine oil of the correct speciﬁcation. Refer to Operation and Maintenance Manual, “Engine Oil

3. If the fault is still apparent, proceed to “Engine Oil Pressure G

nce Manual, “Reﬁll Capacities and

y, drain the oil system and reﬁll the oil

and Filter - Change”.

auge”.

Engine Oil Pressure Gauge

1. Check the actual engine oil pressure with a

calibrated test gauge. Compare the oil pressure reading f pressure on the test gauge.

2. If no dif pressures, proceed to “Engine Oil Filter”.

Engine O

1. Remove the engine oil ﬁlter. Refer to the Operation

and Mai

- Change”.

2. Inspec blockage.

3. Insta Operation and Maintenance Manual, “Engine Oil and Filter - Change”.

4. If the fault is still apparent, proceed to “Engine Oil Cooler”.

rom the electronic service tool to the

ference is noted between the indicated oil

il Filter

ntenance Manual, “Engine Oil and Filter

t the engine oil ﬁlter for evidence of

ll a new engine oil ﬁlter. Refer to the

Engine oil ﬁlter

•

Engine oil cooler

•

ston cooling jets

•

Engine oil suction tube

•

Engine oil pump

•

earing clearance

•

ecommended Actions

Engine Oil Level

1. Check the engine oil level. If necessary, add oil.

Engine Oil Cooler

l ﬂow or coolant ﬂow through the oil cooler

1. If oi is suspected of being low, replace the oil cooler . Refer to Disassembly and Assembly, “Engine

Cooler - Remove” and Disassembly and

Oil Assembly, “Engine Oil Cooler - Install”.

he fault is still apparent, proceed to “Piston

2. If t Cooling Jets”.

ston Cooling Jets

1. Inspect the piston cooling jets for damage.

place any piston cooling jet that appears to be

Re cracked, broken or missing. Refer to Disassembly and Assembly, “Piston Cooling Jets - Remove

nd Install”.

Page 64

This document is printed from SPI². Not for RESALE

64 KENR6201-01 Troubleshooting Section

2. If no damage is found, proceed to “Engine Oil Suction Tube”.

Engine Oil Suction Tube

1. Check the inlet screen on the oil suction tube

and remove any material that may be restricting oil ﬂow.

2. Check the joints of the oil suction tube for cracks or a damaged the supply to the oil pump.

3. If no faults Pump”.

Engine Oil

1. Inspect the components of the engine oil pump for

excessive the oil pump, if necessary. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove”, Disassem Install” and Disassembly and Assembly, “Engine Oil Relief Valve - Remove and Install”.

joint that may allow air leakage into

are found, proceed to “Engine Oil

Pump

wear. Repair the oil pump or replace

bly and Assembly, “Engine Oil Pump -

Val ve la sh

•

Turbocharger

•

Fuel supply

•

Low compression (cylinder pressure)

•

Individual malfunctioning cylinder

•

Electronic

•

Recommende

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

unit injectors

dActions

NOTICE

k the engine continuously for more than

Diagnostic Codes

Check for service tool. Troubleshoot any active codes before continuing with this procedure.

active diagnostic codes on the electronic

2. If no faults are found, proceed to “Bearing Clearance”.

Bearing Clearance

t the engine components for excessive bearing

Inspec clearance or damaged bearings. If necessary, replace the bearings and/or the components. Inspect

lowing components for excessive bearing

the fol clearance:

shaft main bearings

Crank

•

Connecting rod bearings

•

Camshaft front bearing

•

r gear bearing

Idle

•

i03809129

Low Power

Probable Causes

Diagnostic codes

•

ECM parameters

•

Electrical connectors

•

Air intake and exhaust system

•

ECM Parameters

1. Ensure t

parameter.

2. Use the correct mode was selected.

3. Use the correct engine rating has been provided.

4. Use th maximum engine speed limit.

5. Use t parameters to the OEM speciﬁcations.

6. Ensu performance.

7. If t proceed to “Electrical Connectors”.

ctrical Connectors

Ele

1. Turn the keyswitch to the ON position.

2. Use the electronic service tool to verify that the

intake manifold pressure is 0 kPa (0 psi). Check th pressure. Refer to Troubleshooting, “5 Volt Sensor Supply Circuit - Test”.

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

hat the fault is not a programmed

electronic service tool to ensure that the

electronic service tool to verify that the

e electronic service tool to verify the

he electronic service tool to reset the

re that the repairs have eliminated the poor

he repairs have not eliminated the faults

e 5 Volt sensor supply for the intake manifold

Page 65

This document is printed from SPI². Not for RESALE

KENR6201-01 65

Troubleshooting Section

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

5. If the maximum no-load speed of the engine is erratic refer Circuit (Analog) - Test” or Troubleshooting, “Speed Demand Circuit (Digital) - Test”.

6. If the fault has not been eliminated, proceed to “Air Intake and Exhaust System”.

d speed.

to Troubleshooting, “Speed Demand

Air Intake and Exhaust System

1. Check the ai

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

3. Check the air intake and the exhaust system for

the following defects:

Blockages

•

Restrict

•

Damage to the air intake and exhaust lines and

•

hoses

r ﬁlter restriction indicator , if equipped.

ions

5. Check that the turbine blades rotate freely in the turbocharger.

6. Ensure that the wastegate on the turbocharger is adjusted corr Testing and Adjusting, “Turbocharger - Inspect”. If the wastegate actuator is faulty, replace the wastegate ac Assembly, “Turbocharger - Disassemble” and Disassembly and Assembly, “Turbocharger Assemble”.

7. If necessary, replace the turbocharger. Refer to Disassem

- Remove” and Disassembly and Assembly, “Turbocharger - Install”.

8. Check that the repairs have eliminated the faults.

9. If the faul

“Fuel Supply”.

Fuel Supp

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

gauge ma

ectly. Refer to Systems Operation,

tuator. Refer to Disassembly and

bly and Assembly, “Turbocharger

t has not been eliminated, proceed to

ybefaulty.

4. Make all necessary repairs to the engine.

5. If the fault has not been eliminated, proceed to

“Valve Lash”.

Valve Lash

1. Check t

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

2. If the repair does not eliminate the fault proceed to “Tu

he valve lash and reset the valve lash, if

t”.

rbocharger”.

Turbocharger

Note: The turbocharger that is installed on this

engine is a nonserviceable item. If any mechanical

t exists, except for the wastegate actuator, then

faul the turbocharger must be replaced. The wastegate actuator can be replaced.

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

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

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

4. Check that the turbine housing for the turbocharger is free of dirt and debris.

2. Ensure that the fuel supply valve (if equipped) is in the fu

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

4. Check the primary ﬁlter/water separator for water in the f

5. Check for fuel supply lines that are restricted.

6. Check that the low pressure fuel lines are tight

and secured properly.

7. Check the fuel ﬁlters.

8. Chec

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

9. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, “Air in Fuel Te s

10. Ensure that the fuel system has been primed. Ref Adjusting, “Fuel System - Prime”.

11.Ch

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

12. If the repair does not eliminate the fault, proceed to “Low Compression (Cylinder Pressure)”.

ll OPEN position.

idiﬁed fuel (wax).

uel.

k the diesel fuel for contamination. Refer to

t”.

er to Systems Operation, Testing and

eck the fuel pressure. Refer to Systems

Page 66

This document is printed from SPI². Not for RESALE

66 KENR6201-01 Troubleshooting Section

Low Compression (Cylinder Pressure)

1. Perform a compression test. Refer to Systems

Operation, Testing and Adjusting, “Compression

-Test”.

2. If low compression is noted on any cylinders, investigate

Possible causes of low compression are shown in the follo

Loose glow plugs

•

Faulty piston

•

Faulty pis

•

Worn cylinder bores

•

Worn valves

•

Faulty cy

•

Damaged cylinder head

•

3. Perform all necessary repairs.

4. Ensure t

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

“Electr

the cause and rectify any faults.

wing list:

ton rings

linder head gasket

hat the repairs have eliminated the faults.

onic Unit Injectors”.

Electronic Unit Injectors

Individual M alfunctioning Cylinders

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

Mechanic

there is any reduction in engine

If the isolation of a particular cylinder

elow normal performance. Investigate

der that is operating below normal

i02529009

al Noise (Knock) in

Engine

Probabl

Accessory equipment

•

Valve train components

•

Piston

•

Connecting rod and main bearings

•

eCauses

1. With the engine speed at a fast idle, use the electronic service tool to isolate one cylinder at

. Note if there is any reduction in engine

atime speed. If a reduction in engine speed is not noted, the isolated electronic unit injector is not operating

normal conditions. If the isolation of a

under particular cylinder results in a reduction of engine speed that is less than normal, this may indicate

the electronic unit injector is operating below

that normal performance.

2. Remo

3. Install a new electronic unit injector. Refer to

4. Repeat the test in 1. If the fault is still apparent,

ve the electronic unit injector from the suspect cylinder. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”.

Disassembly and Assembly, “Electronic Unit

ector - Install”.

Inj

move the replacement electronic unit injector

re and install the original electronic unit injector. Refer to Disassembly and Assembly, “Electronic

it Injector - Remove” and Disassembly and

Un Assembly, “Electronic Unit Injector - Install”.

Recommended Actions

Accessory Equipment

ate the source of the noise. Remove the

1. Isol suspect engine accessory. Inspect the suspect engine accessory. Repair the engine accessory

or replace the engine accessory if any defects

and/ are found.

he mechanical noise is still apparent, refer to

2. If t “V alve Train Components”.

ve Train Components

Val

1. Remove the valve mechanism cover. Check

e following items for damage: camshaft, valve

th springs, lifters, pushrods, and bridges. Thoroughly clean the valve train components. If the camshaft

being replaced, also replace the valve lifters.

is Ensure that all of the valves move freely. Replace any damaged parts.

2. If the mechanical noise is still apparent, refer to “Pistons”.

f the fault is not eliminated, proceed to “Individual

5.I

Malfunctioning Cylinders”.

Page 67

This document is printed from SPI². Not for RESALE

KENR6201-01 67

Troubleshooting Section

Pistons

1. Inspect the pistons for damage and wear. Replace

any damaged parts.

2. If the mechanical noise is still apparent, refer to “Connecting Rod and Main Bearings”.

Connecting Rod and Main Bearings

Inspect the Also, inspect the bearing surfaces (journals) on the crankshaft. Replace any damaged parts.

connecting rod and main bearings.

i03809192

Noise Comi ng from Cylinder

Probable Causes

Fuel quality

•

Valve l ash

•

Electronic unit injectors

•

Pistons

•

Recommended Actions

Fuel Quality

1. Check the fuel quality. Refer to Systems

Operation, Testing and Adjusting, “Fuel Quality Tes t ” .

2. If unsatisfactory fuel is found, perform the following procedure.

a. Drain the fuel system.

Valve Lash

1. Refer to Troubleshooting, “Excessive Valve Lash”.

2. If the fault ha

“Electronic Unit Injectors”.

Electronic U

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

electronic a time. Note if there is any reduction in engine speed. If a reduction in engine speed is not noted, the isolate under normal conditions. If the isolation of a particular cylinder results in a reduction of engine speed that that the electronic unit injector is operating below normal performance.

2. Remove the electronic unit injector from the suspect cylinder. Refer to Disassembly and Assembly

3. Install a new electronic unit injector. Refer to Disasse Injector - Install”.

4. Repeat t remove the replacement electronic unit injector and install the original electronic unit injector. Refer t Unit Injector - R emove” and Disassembly and Assembly, “Electronic Unit Injector - Install”.

5. If the fault has not been eliminated, proceed to “Pistons”.

s not been eliminated, proceed to

nit Injectors

servicetooltoisolateonecylinderat

d electronic unit injector is not operating

is less than normal, this may indicate

, “Electronic Unit Injector - Remove”.

mbly and Assembly, “Electronic Unit

he test in 1. If the noise is still apparent,

o Disassembly and Assembly, “Electronic

Pistons

1. Inspe

ct the pistons for damage and wear. Replace

any damaged parts.

b. Replace the fuel ﬁlters. Refer to the Operation

and Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element Replace” and Operation and Maintenance Manual, “Fuel System Filter - Replace”.

c. Fill the fuel system with fuel that meets the

standard in Operation and Maintenance Manual, “Fluid Recommendations”.

d. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System - Prime”.

3. If the fault is not eliminated, proceed to “Valve Lash”.

Page 68

This document is printed from SPI². Not for RESALE

68 KENR6201-01 Troubleshooting Section

Troubleshooti

ng with a

Diagnostic Code

i03809150

Diagnostic Code Cross Reference

Table 31

3rd Party

CDL Code Description

0001-02 Cylinder #1 Injector Data Incorrect 651-2 71

0001-05 Cylinder #1 Injector open circuit 651-5 71

0001-06 Cylinder #1 Injector short 651-6 71

0001-07 Cylinder #1 Injector Not Responding 651-7 71

0002-02 Cylinder #2 Injector Data Incorrect 652-2 72

0002-05

0002-06

0002-07

0003-02

0003-05

0003-06 Cylinder #3 Injector short 653-6 73

0003-07 Cylinder #3 Injector Not Responding 653-7 73

0004-02 Cylinder #4 Injector Data Incorrect 654-2 74

0004-05 Cylinder #4 Injector open circuit 654-5 74

0004-06 Cylinder #4 Injector short 654-6 74

0004-07 Cylinder #4 Injector Not Responding 654-7 74

0005-02 Cylinder #5 Injector Data Incorrect 655-2 75

0005-05 Cylinder #5 Injector open circuit 655-5 75

0005-06

0005-07

0006-02

0006-05

0006-06 Cylinder #6 Injector short 656-6 76

0006-07 Cylinder #6 Injector Not Responding 656-7 76

0041-03 8 Volt DC Supply short to +batt 678-03 21

0041-04 8 Volt DC Supply short to ground 678-04 21

0091-08 Throttle Position signal abnormal 91-08 32

0100-03

0100-04

er #2 Injector open circuit 652-5 72

Cylind

Cylinder #2 Injector short

Cylinder #2 Injector Not Responding

Cylinder #3 Injector Data Incorrect

Cylinder #3 Injector open circuit

Cylinder #5 Injector short

Cylinder #5 Injector Not Responding

Cylinder #6 Injector Data Incorrect

Cylinder #6 Injector open circuit

Engine Oil Pressure open/short to +batt

Engine Oil Pressure short to ground

Device

J1939

Code

652-6 72

652-27 72

653-2 73

653-5 73

655-6 75

655-7 75

656-2 76

656-5 76

100-03 24

100-04 24

Flash

Code

(continued)

Page 69

This document is printed from SPI². Not for RESALE

KENR6201-01 69

Troubleshooting Section

(Table 31, cont

CDL Code Description

0100-10

0110-03

0110-04

0168-00

0168-01 System Voltage Low 168-01 51

0168-02 System Voltage intermittent/erratic 168-02 51

0172-03 Intake Manifold Air Temp open/short to +batt 105-03 38

0172-04 Intake Manifold Air Temp short to ground 105-04 38

0190-08 Engine Speed signal abnormal 190-08 34

0247-09 J1939 Data Link communications 639-09 65

0253-02 Personality Module mismatch 631-02 56

0261-11 Engine Timing Calibration invalid 637-11 42

0262-03 5 Volt Sensor DC Power Supply short to +batt 1079-03 21

0262-04 5 Volt Sensor DC Power Supply short to ground 1079-04 21

0268-02 Check Programmable Parameters 630-02 56

0342-08 Secondary Engine Speed signal abnormal 723-08 34

0526-05 Turbo Wastegate Drive current low 1188-05 33

0526-06 Turbo Wastegate Drive current high 1188-06 33

1690-08 Analog Speed Demand Abnormal signal 29-08 66

1779-05 Fuel Rail Pressure Valve 1 Solenoid open circuit 1347-05 47

1779-06 Fuel Rail Pressure Valve 1 Solenoid short to ground 1347-06 47

1779-08 Fuel Rail Pressure Valve 1 Solenoid abnormal frequency, pulse width or period 1347-08 47

1785-03 Intake Manifold Pressure Sensor voltage high 102-03 25

1785-04 Intake Manifold Pressure Sensor voltage low 102-04 25

1785-10

1797-03

1797-04

1834-02

2246-06 Glow plug Start Aid Relay Current High 676-06

E085-1 Shutdown Overriden 1237-1 12

E255-1 Diagnostic Reset 704-00 59

E264-3 E-Stop Shutdown 970-31 58

E360-1

E360-3

E361-1

E361-2

Engine Oil Pressure Sensor abmormal rate of change

Engine Coolant Temperature open/short to +batt

Engine Coolant Temperature short to ground

System Voltage High

Intake Manifold Pressure Sensor abnormal rate of change

Fuel Rail Pressure Sensor open/short to +batt

Fuel Rail Pressure Sensor short to ground

Ignition Keyswitch loss of signal

Event Codes

Low Oil Pressure - Warning

Low Oil Pressure - Shutdown

High Engine Coolant Temperature - Warning

High Engine Coolant Temperature - Derate

3rd Party

Device

J1939

Code

100-10 26

110-03 27

110-04 27

168-00 51

102-04 25

157-03 37

157-04 37

158-02

100-17 24

100-01 24

110-15 27

110-16 27

Flash

Code

(continued)

Page 70

This document is printed from SPI². Not for RESALE

70 KENR6201-01 Troubleshooting Section

(Table 31, cont

CDL Code Description

E361-3

E362-1

E362-3

E396-2 High Fuel Rail Pressure 157-15 47

E398-2 Low Fuel Rail Pressure 157-17 47

E539-1

CID 0001 FMI 02

Conditions Which Generate This Code:

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

Data from the electronic unit injector for the No. 1

•

cylinder is out of limits.

Diagnostic code 0168-01 is not active.

•

Diagno

•

active.

No 004

•

No 0262 diagnostic codes are active.

•

Diagnostic code 0190-08 is not active.

•

High Engine Coolant Temperature - Shutdown

Engine Overspeed - Warning

Engine Overspeed - Sutdown

High Intak

stic codes 0001-05 and 0001-06 are not

1 diagnostic codes are active.

e M anifold Air Temperature - Warning 1636-15 38

i03795209

3rd Party

Device

J1939

Code

110-00 27

190-15 35

190-00 35

CID 0 001 FMI 05

Conditions Which Generate This Code:

This diagnostic code indicates an open circuit (low current) in either the solenoid or the wiring for the

nic unit injector for No. 1 cylinder.

electro

The Electronic Control Module (ECM) detects the

ing condition:

A low current condition (open circuit) for each of

•

ﬁve con

Battery voltage is higher than 9 volts for 2 seconds.

•

System Response:

The E the diagnostic lamp will ﬂ ash.

secutive attempts to operate

CM will log the diagnostic code. If equipped,

Flash

Code

i03795221

10 diagnostic codes are active.

No 01

•

System Response:

If equipped, the diagnostic lamp will ﬂash and the derate lamp will come on. An active diagnostic code

l be generated. The ECM will log the diagnostic

wil code.

ssible Performance Effect:

The engine will be derated while this diagnostic code

active.

Troubleshooting:

Perform the following diagnostic procedure: “Injector Data Incorrect - Test”

Results:

K–STOP.

•

ible Performance Effect:

Poss

The engine will have low power and/or rough running.

Troubleshooting:

n the “Injector Cutout Test” is performed, a faulty

Whe electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors.

An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring

at is unique to the electronic unit injector will prevent

th that individual electronic unit injector from operating. An open circuit in common wiring within the ECM can

event the three electronic unit injectors that share

pr that common wiring from operating.

Page 71

This document is printed from SPI². Not for RESALE

KENR6201-01 71

Troubleshooting Section

The ECM will continue to attempt to operate the electronic uni been logged but an open circuit will prevent the operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

CID 0001 FMI

Conditions Which Generate This Code:

This diagn current) in either the solenoid or the wiring for the electronic unit injector for No. 1 cylinder.

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

A high current condition (short circuit) for each of

•

ﬁve consecutive attempts to operate

t injector after the diagnostic code has

i03795249

ostic code indicates a short circuit (high

Results:

OK – STOP.

•

i03795297

CID 0 001 FMI 07

Conditions Which Generate This Code:

The electronic unit injector is no longer capable of delivering the correct amount of fuel.

System Response:

If equippe derate lamp will come on. The Electronic Control Module (ECM) will log the diagnostic code.

Note: Thediagnosticcodecanbeviewedonthe electronic service tool.

Possible Performance Effect:

The engi

Troubleshooting:

d, the diagnostic lamp will ﬂash and the

ne will be derated by 20%.

Battery voltage above 9 volts for 2 seconds

•

System

The ECM will log the diagnostic code. If equipped, the dia

Possible Performance Effect:

The engine will have low power and/or rough running.

Troub

When the “Injector Cutout Test” is performed, a faulty elec comparison with the other electronic unit injectors.

An el injector from operating. A short circuit in the wiring or the ECM that is unique to one electronic unit injector wil operating. A short circuit in common wiring within the ECM can prevent the three electronic unit injectors tha

The ECM will continue to attempt to operate the

ectronic unit injector after the diagnostic code

el has been logged but a short circuit will prevent the operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Response:

gnostic lamp will ﬂash.

leshooting:

tronic unit injector will indicate a low reading in

ectrical fault can prevent the electronic unit

l prevent that individual electronic unit injector from

t share that common wiring from operating.

Replace the suspect electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit

or - Remove” and Disassembly and Assembly,

Inject “Electronic Unit Injector - Install”.

Use the System Veriﬁcation Test.

Perfo

Results:

•

electronic service tool to perform the Fuel

rm the following diagnostic procedure: “None”

OK – STOP.

i03795363

CID 0 002 FMI 02

Conditions Which Generate This Code:

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

Data from the electronic unit injector for the No. 2

•

cylinder is out of limits.

Diagnostic code 0168-01 is not active.

•

iagnostic codes 0002-05 and 0002-06 are not

•

active.

Page 72

This document is printed from SPI². Not for RESALE

72 KENR6201-01 Troubleshooting Section

No 0041 diagnostic codes are active.

•

No 0262 diagnostic codes are active.

•

Diagnostic co

•

No 0110 diagnostic codes are active.

•

System Response:

If equipped derate lamp will come on. An active diagnostic code will be generated. The ECM will log the diagnostic code.

Possible Performance Effect:

The engine will be derated while this diagnostic code is active.

Troubleshooting:

Perform t Data Incorrect - Test”

Results:

OK – STOP.

•

de 0190-08 is not active.

, the diagnostic lamp will ﬂash and the

he following diagnostic procedure: “Injector

i037953

CID 0002 FMI 05

An electrical fault can prevent the electronic unit injector from o that is unique to the electronic unit injector will prevent that individual electronic unit injector from operating. An open circui prevent the three electronic unit injectors that share that common wiring from operating.

The ECM will continue to attempt to operate the electronic unit injector after the diagnostic code has been logged operation of the electronic unit injector.

Perform the Solenoid Circuit - Test”

Results:

OK – STOP.

•

perating. An open circuit in the wiring

tincommonwiringwithintheECMcan

but an open circuit will prevent the

following diagnostic procedure: “Injector

i03795504

CID 0 002 FMI 06

Conditi

This diagnostic code indicates a short circuit (high

current electronic unit injector for No. 2 cylinder.

The Ele following conditions:

ons Which Generate This Code:

) in either the solenoid or the wiring for the

ctronic Control Module (ECM) detects the

Condit

This diagnostic code indicates an open circuit (low curre electronic unit injector for No. 2 cylinder.

The El following condition:

•

System Response:

The ECM will log the diagnostic code. If equipped, the diagnostic lamp will ﬂash.

Possible Performance Effect:

Troubleshooting:

When the “Injector Cutout Test” is performed, a faulty electronic unit injector will indicate a low reading in c

ions Which Generate This Code:

nt) in either the solenoid or the wiring for the

ectronic Control Module (ECM) detects the

current condition (open circuit) for each of

Alow ﬁve consecutive attempts to operate

ery voltage is higher than 9 volts for 2 seconds.

Batt

e engine will have low power and/or rough running.

omparison with the other electronic unit injectors.

Ahighc

•

ﬁve consecutive attempts to operate

Batte

•

System Response:

The ECM will log the diagnostic code. If equipped, the diagnostic lamp will ﬂ ash.

Possible Performance Effect:

The e

Troubleshooting:

When the “Injector Cutout Test” is performed, a faulty electronic unit injector will indicate a low reading in com

An electrical fault can prevent the electronic unit

jector from operating. A short circuit in the wiring or

in the ECM that is unique to one electronic unit injector will prevent that individual electronic unit injector from

erating. A short circuit in common wiring within the

op ECM can prevent the three electronic unit injectors that share that common wiring from operating.

urrent condition (short circuit) for each of

ry voltage above 9 volts for 2 seconds

ngine will have low power and/or rough running.

parison with the other electronic unit injectors.

Page 73

This document is printed from SPI². Not for RESALE

KENR6201-01 73

Troubleshooting Section

The ECM will continue to attempt to operate the electronic uni has been logged but a short circuit will prevent the operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

CID 0002 FMI

Conditions Which Generate This Code:

The electr delivering the correct amount of fuel.

System Re

If equipped, the diagnostic lamp will ﬂash and the derate l Module (ECM) will log the diagnostic code.

Note: Th electronic service tool.

Possib

The engine will be derated by 20%.

Troubleshooting:

ce the suspect electronic unit injector. Refer

Repla to Disassembly and Assembly, “Electronic Unit Injector - Remove” and Disassembly and Assembly,

tronic Unit Injector - Install”.

“Elec

t injector after the diagnostic code

i03795537

onic unit injector is no longer capable of

sponse:

amp will come on. The Electronic Control

e diagnostic code can be viewed on the

le Performance E ffect:

Data from the electronic unit injector for the No. 3

•

cylinder is out

Diagnostic code 0168-01 is not active.

•

Diagnostic codes 0003-05 and 0003-06 are not

•

active.

No 0041 diagnostic codes are active.

•

No 0262 diag

•

Diagnostic code 0190-08 is not active.

•

No 0110 diagnostic codes are active.

•

System Res

If equipped, the diagnostic lamp will ﬂash and the derate lam will be generated. The ECM will log the diagnostic code.

Possible Performance Effect:

The engin is active.

Trouble

Perform the following diagnostic procedure: “Injector Data Inc

Results:

•

shooting:

orrect - Test”

OK – STOP.

of limits.

nostic codes are active.

ponse:

p will come on. An active diagnostic code

e will be derated while this diagnostic code

i03795592

CID 0 003 FMI 05

Use the electronic service tool to perform the Fuel

em Veriﬁcation Test.

Syst

Perform the following diagnostic procedure: “None”

Results:

STOP.

OK –

•

i03795549

D 0003 FMI 02

Conditions Which Generate This Code:

he Electronic Control Module (ECM) detects the

T following condition:

Conditions Which Generate This Code:

This diagnostic code indicates an open circuit (low current) in either the solenoid or the wiring for the

tronic unit injector for No. 3 cylinder.

elec

The Electronic Control Module (ECM) detects the

lowing condition:

fol

A low current condition (open circuit) for each of

•

consecutive attempts to operate

ﬁve

Battery voltage is higher than 9 volts for 2 seconds.

•

System Response:

e ECM will log the diagnostic code. If equipped,

Th the diagnostic lamp will ﬂ ash.

Page 74

This document is printed from SPI². Not for RESALE

74 KENR6201-01 Troubleshooting Section

Possible Performance Effect:

The engine will have low power and/or rough running.

Troubleshoot

When the “Injector Cutout Test” is performed, a faulty electronic u comparison with the other electronic unit injectors.

An electric injector from operating. An open circuit in the wiring that is unique to the electronic unit injector will prevent that indivi An open circuit in common wiring within the ECM can prevent the three electronic unit injectors that share that commo

The ECM will continue to attempt to operate the electroni been logged but an open circuit will prevent the operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP

•

ing:

nit injector will indicate a low reading in

al fault can prevent the electronic unit

dual electronic unit injector from operating.

n wiring from operating.

c unit injector after the diagnostic code has

Troubleshooting:

When the “Injector Cutout Test” is performed, a faulty electronic unit injector will indicate a low reading in comparison wi

An electrical fault can prevent the electronic unit injector fro the ECM that is unique to one electronic unit injector will prevent that individual electronic unit injector from operating. ECM can prevent the three electronic unit injectors that share that common wiring from operating.

The ECM will continue to attempt to operate the electronic unit injector after the diagnostic code has been lo operation of the electronic unit injector.

Perform th Solenoid Circuit - Test”

Results:

OK – STOP.

•

th the other electronic unit injectors.

m operating. A short circuit in the wiring or

Ashortcircuitincommonwiringwithinthe

gged but a short circuit will prevent the

e following diagnostic procedure: “Injector

i037970

CID 0 003 FMI 07

i03795600

CID 000

Conditions Which Generate This Code:

iagnostic code indicates a short circuit (high

This d current) in either the solenoid or the wiring for the electronic unit injector for No. 3 cylinder.

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

A high current condition (short circuit) for each of

•

ﬁve consecutive attempts to operate

Battery voltage above 9 volts for 2 seconds

•

tem Response:

Sys

The ECM will log the diagnostic code. If equipped,

diagnostic lamp will ﬂash.

the

Possible Performance Effect:

3FMI06

Condit

The electronic unit injector is no longer capable of delive

System Response:

If equipped, the diagnostic lamp will ﬂash and the derate lamp will come on. The Electronic Control Modul

Note: Thediagnosticcodecanbeviewedonthe elec

Possible Performance Effect:

The engine will be derated by 20%.

Tro

Replace the suspect electronic unit injector. Refer to D Injector - Remove” and Disassembly and Assembly, “Electronic Unit Injector - Install”.

ions Which Generate This Code:

ring the correct amount of fuel.

e (ECM) will log the diagnostic code.

tronic service tool.

ubleshooting:

isassembly and Assembly, “Electronic Unit

The engine will have low power and/or rough running.

Use the electronic service tool to perform the Fuel System Veriﬁcation Test.

Perform the following diagnostic procedure: “None”

Page 75

This document is printed from SPI². Not for RESALE

KENR6201-01 75

Troubleshooting Section

Results:

OK – STOP.

•

i03797010

CID 0004 FMI 02

Conditions Which Generate This Code:

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

Data from the electronic unit injector for the No. 4

•

cylinder is out of limits.

Diagnostic code 0168-01 is not active.

•

Diagnosti

•

active.

No 0041 di

•

No 0262 diagnostic codes are active.

•

Diagnostic code 0190-08 is not active.

•

No 0110 d

•

System Response:

If equipped, the diagnostic lamp will ﬂash and the derate lamp will come on. An active diagnostic code will be code.

Possi

The engine will be derated while this diagnostic code is act

Troubleshooting:

Perform the following diagnostic procedure: “Injector Data Incorrect - Test”

Results:

c codes 0004-05 and 0004-06 are not

agnostic codes are active.

iagnostic codes are active.

generated. The ECM will log the diagnostic

ble Performance Effect:

ive.

i03797011

CID 0 004 FMI 05

Conditions Which Generate This Code:

This diagnostic code indicates an open circuit (low current) in either the solenoid or the wiring for the electronic u

The Electronic Control Module (ECM) detects the following c

A low current condition (open circuit) for each of

•

ﬁve consec

Battery voltage is higher than 9 volts for 2 seconds.

•

System Response:

The ECM wi the diagnostic lamp will ﬂ ash.

Possible

The engine will have low power and/or rough running.

Troubleshooting:

When the electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors.

An electrical fault can prevent the electronic unit injector from operating. An open circuit in the wiring that i that individual electronic unit injector from operating. An open circuit in common wiring within the ECM can preve that common wiring from operating.

The E electronic unit injector after the diagnostic code has been logged but an open circuit will prevent the

ation of the electronic unit injector.

oper

Perform the following diagnostic procedure: “Injector

enoid Circuit - Test”

Sol

nit injector for No. 4 cylinder.

ondition:

utive attempts to operate

ll log the diagnostic code. If equipped,

Performance Effect:

“Injector Cutout Test” is performed, a faulty

s unique to the electronic unit injector will prevent

nt the three electronic unit injectors that share

CM will continue to attempt to operate the

•

Results:

OK – STOP.

•

STOP.

OK –

Page 76

This document is printed from SPI². Not for RESALE

76 KENR6201-01 Troubleshooting Section

i03797012

CID 0004 FMI 06

Conditions Which Generate This Code:

This diagnostic code indicates a short circuit (high current) in either the solenoid or the wiring for the electronic u

The Electronic Control Module (ECM) detects the following c

A high current condition (short circuit) for each of

•

ﬁve consec

Battery voltage above 9 volts for 2 seconds

•

System Response:

The ECM wi the diagnostic lamp will ﬂash.

Possible

The engine will have low power and/or rough running.

Troubleshooting:

nit injector for No. 4 cylinder.

onditions:

utive attempts to operate

ll log the diagnostic code. If equipped,

Performance Effect:

i03797013

CID 0 004 FMI 07

Conditions Which Generate This Code:

The electronic unit injector is no longer capable of delivering the correct amount of fuel.

System Response:

If equipped Electronic Control Module (ECM) will log the diagnostic code.

Note: Thediagnosticcodecanbeviewedonthe electronic service tool.

Possible Performance Effect:

The engin

Troubleshooting:

Replace the suspect electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injecto “Electronic Unit Injector - Install”.

, the derate lamp will come on. The

e will be derated by 20%.

r - Remove” and Disassembly and Assembly,

When the electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors.

An electrical fault can prevent the electronic unit injector from operating. A short circuit in the wiring or the EC will prevent that individual electronic unit injector from operating. A short circuit in common wiring within the ECM ca that share that common wiring from operating.

The E electronic unit injector after the diagnostic code has been logged but a short circuit will prevent the oper

Perform the following diagnostic procedure: “Injector

enoid Circuit - Test”

Sol

Results:

OK – STOP.

•

“Injector Cutout Test” is performed, a faulty

M that is unique to one electronic unit injector

n prevent the three electronic unit injectors

CM will continue to attempt to operate the

ation of the electronic unit injector.

Use the e System Veriﬁcation Test.

Perfor

Results:

OK – STOP.

•

lectronic service tool to perform the Fuel

m the following diagnostic procedure: “None”

i03797029

CID 0 005 FMI 02

Conditions Which Generate This Code:

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

Data from the electronic unit injector for the No. 5

•

cylinder is out of limits.

Diagnostic code 168-01 is not active.

•

agnostic codes 0005-05 and 0005-06 are not

•

active.

0041 diagnostic codes are active.

•

No 0262 diagnostic codes are active.

•

Page 77

This document is printed from SPI². Not for RESALE

KENR6201-01 77

Troubleshooting Section

Diagnostic code 190-08 is not active.

•

No 0110 diagnostic codes are active.

•

System Respon

If equipped, the diagnostic lamp will ﬂash and the derate lamp w will be generated. The ECM will log the diagnostic code. The ECM will trigger a snapshot.

Possible Performance Effect:

The engine w is active.

Troublesh

Perform the following diagnostic procedure: “Injector Data Incor

Results:

OK – STOP.

•

se:

ill come on. An active diagnostic code

ill be derated while this diagnostic code

ooting:

rect - Test”

i03797030

CID 0005 FMI 05

Conditions Which Generate This Code:

This diagnostic code is designed to indicate an open circuit (low current) in either the solenoid or the wiring for the

The Electronic Control Module (ECM) detects the follo

electronic unit injector for No. 5 cylinder.

wing condition:

The ECM will continue to attempt to operate the electronic unit injector after the diagnostic code has been logged operation of the electronic unit injector.

Perform the Solenoid Circuit - Test”

Results:

OK – STOP.

•

perating. An open circuit in the wiring

tincommonwiringwithintheECMcan

but an open circuit will prevent the

following diagnostic procedure: “Injector

i03797033

CID 0 005 FMI 06

Conditi

This diagnostic code is designed to indicate a short circuit wiring for the electronic unit injector for No. 5 cylinder.

The Ele following conditions:

•

ons Which Generate This Code:

(high current) in either the solenoid or the

ctronic Control Module (ECM) detects the

Ahighc ﬁve consecutive attempts to operate

Batte

urrent condition (short circuit) for each of

ry voltage above 9 volts for 2 seconds

A low current condition (open circuit) for each of

•

System Response:

The E the diagnostic lamp will ﬂash.

Pos

The engine will have low power and/or rough running.

Troubleshooting:

Wh electronic unit injector will indicate a low reading in comparison with the other electronic unit injectors.

nsecutive attempts to operate

ﬁve co

Battery voltage is higher than 9 volts for 2 seconds.

CM will log the diagnostic code. If equipped,

sible Performance Effect:

en the“ Injector Cutout Test” is performed, a faulty

System Response:

The ECM will log the diagnostic code. If equipped, the diagnostic lamp will ﬂ ash.

Possible Performance Effect:

ngine will have low power and/or rough running.

The e

Troubleshooting:

When the “Injector Cutout Test” is performed, a faulty electronic unit injector will indicate a low reading in

parison with the other electronic unit injectors.

com

An electrical fault can prevent the electronic unit

jector from operating. A short circuit in the wiring or

in the ECM that is unique to one electronic unit injector will prevent that individual electronic unit injector from

erating. A short circuit in common wiring within the

op ECM can prevent the three electronic unit injectors that share that common wiring from operating.

Page 78

This document is printed from SPI². Not for RESALE

78 KENR6201-01 Troubleshooting Section

The ECM will continue to attempt to operate the electronic uni has been logged but a short circuit will prevent the operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP.

•

CID 0005 FMI

Conditions Which Generate This Code:

The electr delivering the correct amount of fuel.

System Re

If equipped, the diagnostic lamp will ﬂash and the derate l Module (ECM) will log the diagnostic code.

Note: Th electronic service tool.

Possib

The engine will be derated by 20%.

Troubleshooting:

ce the suspect electronic unit injector. Refer

Repla to Disassembly and Assembly, “Electronic Unit Injector - Remove” and Disassembly and Assembly,

tronic Unit Injector - Install”.

“Elec

t injector after the diagnostic code

i03797050

onic unit injector is no longer capable of

sponse:

amp will come on. The Electronic Control

e diagnostic code can be viewed on the

le Performance E ffect:

Data from the electronic unit injector for the No. 6

•

cylinder is out

Diagnostic code 168-01 is not active.

•

Diagnostic codes 0006-05 and 0006-06 are not

•

active.

No 0041 diagnostic codes are active.

•

No 0262 diag

•

Diagnostic code 190-08 is not active.

•

No 0110 diagnostic codes are active.

•

System Res

If equipped, the diagnostic lamp will ﬂash and the derate lam will be generated. The ECM will log the diagnostic code. The ECM will trigger a snapshot.

Possible Performance Effect:

The engin is active.

Trouble

Perform the following diagnostic procedure: “Injector Data Inc

Results:

•

shooting:

orrect - Test”

OK – STOP.

of limits.

nostic codes are active.

ponse:

p will come on. An active diagnostic code

e will be derated while this diagnostic code

i03797069

CID 0 006 FMI 05

Use the electronic service tool to perform the Fuel

em Veriﬁcation Test.

Syst

Perform the following diagnostic procedure: “None”

Results:

STOP.

OK –

•

i03797051

D 0006 FMI 02

Conditions Which Generate This Code:

he Electronic Control Module (ECM) detects the

T following condition:

Conditions Which Generate This Code:

This diagnostic code is designed to indicate an open circuit (low current) in either the solenoid or the wiring

he electronic unit injector for No. 6 cylinder.

for t

The Electronic Control Module (ECM) detects the

lowing condition:

fol

A low current condition (open circuit) for each of

•

consecutive attempts to operate

ﬁve

Battery voltage is higher than 9 volts for 2 seconds.

•

System Response:

e ECM will log the diagnostic code. If equipped,

Th the diagnostic lamp will ﬂ ash.

Page 79

This document is printed from SPI². Not for RESALE

KENR6201-01 79

Troubleshooting Section

Possible Performance Effect:

The engine will have low power and/or rough running.

Troubleshoot

When the “Injector Cutout Test” is performed, a faulty electronic u comparison with the other electronic unit injectors.

The ECM will continue to attempt to operate the electroni been logged but an open circuit will prevent the operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Solenoid Circuit - Test”

Results:

OK – STOP

•

ing:

nit injector will indicate a low reading in

al fault can prevent the electronic unit

dual electronic unit injector from operating.

n wiring from operating.

c unit injector after the diagnostic code has

Troubleshooting:

When the “Injector Cutout Test” is performed, a faulty electronic unit injector will indicate a low reading in comparison wi

The ECM will continue to attempt to operate the electronic unit injector after the diagnostic code has been lo operation of the electronic unit injector.

Perform th Solenoid Circuit - Test”

Results:

OK – STOP.

•

th the other electronic unit injectors.

m operating. A short circuit in the wiring or

Ashortcircuitincommonwiringwithinthe

gged but a short circuit will prevent the

e following diagnostic procedure: “Injector

i037970

CID 0 006 FMI 07

i03797070

CID 000

Conditions Which Generate This Code:

iagnostic code is designed to indicate a short

This d circuit (high current) in either the solenoid or the wiring for the electronic unit injector for No. 6 cylinder.

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

A high current condition (short circuit) for each of

•

ﬁve consecutive attempts to operate

Battery voltage above 9 volts for 2 seconds

•

tem Response:

Sys

The ECM will log the diagnostic code. If equipped,

diagnostic lamp will ﬂash.

the

Possible Performance Effect:

6FMI06

Condit

The electronic unit injector is no longer capable of delive

System Response:

If equipped, the diagnostic lamp will ﬂash and the derate lamp will come on. The Electronic Control Modul

Note: Thediagnosticcodecanbeviewedonthe elec

Possible Performance Effect:

The engine will be derated by 20%.

Tro

Replace the suspect electronic unit injector. Refer to D Injector - Remove” and Disassembly and Assembly, “Electronic Unit Injector - Install”.

ions Which Generate This Code:

ring the correct amount of fuel.

e (ECM) will log the diagnostic code.

tronic service tool.

ubleshooting:

isassembly and Assembly, “Electronic Unit

The engine will have low power and/or rough running.

Use the electronic service tool to perform the Fuel System Veriﬁcation Test.

Perform the following diagnostic procedure: “None”

Page 80

This document is printed from SPI². Not for RESALE

80 KENR6201-01 Troubleshooting Section

Results:

OK – STOP.

•

i03797073

CID 0041 FMI 03

Conditions Which Generate This Code:

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

The 8 volt supply is more than 8.8 VDC for more

•

than one second.

The ECM has been powered for more than three

•

seconds.

Diagnostic code 168-01 is not active.

•

System Re

The ECM will log the diagnostic code. If equipped, the diag code may not cause any noticeable effect on engine response unless the voltage is above 12 or 13 VDC.

sponse:

nostic lamp will ﬂash. An active diagnostic

Diagnostic code 168-01 is not active at the same

•

time.

System Response:

The ECM will log the diagnostic code. If equipped, the diagnostic lamp will ﬂash. An active diagnostic code may not c response unless the voltage drops below 6.5 VDC.

Possible Pe

Theenginemaybelimitedtolowidle.

Troubleshooting:

This signa If this diagnostic code is observed, check the associated wiring on the engine.

Refer to the Engine Electrical Schematic.

Results:

OK – STOP.

•

ause any noticeable effect on engine

rformance Effect:

l is not normally used in this application.

i037970

CID 0 091 FMI 08

Possible Performance Effect:

The eng

Troubleshooting:

This signal is not normally used in this application. If this diagnostic code is observed, check the assoc

Refer to the Engine Electrical Schematic.

Results:

•

CID

Conditions Which Generate This Code:

Th following conditions:

ine may be limited to low idle.

iated wiring on the engine.

OK – S

TOP .

i03797075

0041 FMI 04

e Electronic Control Module (ECM) detects the

Condit

The Electronic Control Module (ECM) detects the follow

•

System Response:

The

If equipped, the diagnostic lamp will ﬂash. The dia running. The diagnostic code will not be logged if the engine is cranking.

ions Which Generate This Code:

ing conditions:

The signal frequency from the digital speed control

it is less than 150 Hz or the signal frequency is

circu greater than 1050 Hz for more than two seconds.

The EC seconds.

Diag

Diagnostic code 91-04 is not active.

gnostic code will be logged if the engine is

M has been powered for at least three

nostic code 91-03 is not active.

ECM sets the “Throttle Position” to “0%”.

e 8 volt supply is less than 7.2 VDC for more

•

than one second.

he ECM has been powered for more than three

•

seconds.

Possible Performance Effect:

e engine may remain at low idle while the

Th diagnostic code is active.

Page 81

This document is printed from SPI². Not for RESALE

KENR6201-01 81

Troubleshooting Section

Troubleshooting:

This diagnostic code indicates that the frequency of a digital throttle signal is out of the normal range.

Perform the following diagnostic procedure: “Speed Control (PWM) - Test”

Results:

OK – STOP.

•

i03797081

CID 0100 FMI

Conditions Which Generate This Code:

The Electr following conditions:

The signa

•

sensor is greater than 4.95 Volts DC for more than eight seconds.

onic Control Module (ECM) detects the

l voltage from the engine oil pressure

i03797131

CID 0 100 FMI 04

Conditions Which Generate This Code:

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

The signal voltage from the engine oil pressure

•

sensor is less than 0.1 Volts DC for more than eight secon

The ECM has been powered for at least two

•

seconds.

The engine is running.

•

System Response:

The ECM wi the diagnostic lamp will ﬂash. The ECM will set data for engine oil pressure to the default value. The electron Normal” on the status screens.

ds.

ll log the diagnostic code. If equipped,

ic service tool will display “Voltage Below

The ECM has been powered for at least two

•

seconds.

The engine is not running or the engine coolant

•

temperature is greater than 38 °C (100 °F).

System Response:

The ECM the diagnostic lamp will ﬂash. The ECM will set data for engine oil pressure to the default value.

Note: The engine oil pressure that is displayed on the electronic service tool is the default value for engin is 600 kPa (87 psi). The electronic service tool will display “Voltage Above Normal” on the status scre

Possible Performance Effect:

None

Tro

This diagnostic code can be caused by an open

cuit or a short to another power source.

cir

will log the diagnostic code. If equipped,

e oil pressure. The default engine oil pressure

ens.

ubleshooting:

Possibl

None

Troubleshooting:

This di ground or a shorted sensor.

Perfo Pressure Sensor Open or Short Circuit - Test”

Resul

•

e Performance Effect:

agnostic code can be caused by a short to

rm the following diagnostic procedure: “Engine

ts:

OK – STOP.

i037

CID 0 100 FMI 10

ditions Which Generate This Code:

Con

The Electronic Control Module (ECM) detects the

lowing conditions:

fol

97149

No other codes for the oil pressure sensor are

Perform the following diagnostic procedure: “Engine

essure Sensor Open or Short Circuit - T est”

Results:

OK – STOP.

•

tive.

No 0262 diagnostic codes are active for the 5 Volt

•

pply.

The engine speed is greater than 600 rpm.

•

Page 82

This document is printed from SPI². Not for RESALE

82 KENR6201-01 Troubleshooting Section

The engine oil pressure signal is within the limits of

•

410 kPa (59 psi) variation of less than 1.68 kPa (0.25 psi)for more than 30 seconds.

The engine oil pressure signal remains constant

•

for 30 seconds.

System Response:

If equipped will log the diagnostic code.

The ECM will data. The data for engine oil pressure is set to a default value of 500 kPa (72 psi). The electronic service to status screen.

Possible P

None

Troubleshooting:

This diag of the 5 Volt supply to the sensor.

Perform Pressure Sensor Open or Short Circuit - Test”

, the diagnostic lamp will ﬂash. The ECM

ol will display “Conditions Not Met” on the

erformance Effect:

nostic code is designed to detect the loss

the following diagnostic procedure: “Engine

to 520 kPa (75 psi) with a pressure

ﬂag the engine oil pressure as invalid

The ECM will default to 90 °C (194 °F) for engine coolant temper be displayed next to the status for “Engine Coolant Temperature” on the electronic service tool.

Possible Performance Effect:

Poor stabili

•

Poor cold running

•

White smoke

•

Troublesho

The diagnostic code will detect an excessively high voltage fr

Perform the following diagnostic procedure: “Engine Temperatu

Results:

OK – STOP.

•

ature. “Voltage Above Normal” will

oting:

om the engine coolant temperature sensor.

re Sensor Open or Short Circuit - Test”

i03797151

CID 0 110 FMI 04

Results

•

OK – STOP.

i03797

CID 0110 FMI 03

tions Which Generate This Code:

Condi

The Electronic Control Module (ECM) detects the

owing conditions:

foll

The signal voltage from the engine coolant

•

Sys

If equipped, the diagnostic lamp will ﬂash. An active di The diagnostic code will be logged if the engine has been operating for more than 7 minutes.

erature sensor is greater than 4.95 Volts DC

temp for more than eight seconds.

ECM has been powered for at least two

The seconds.

tem Response:

agnostic code will be generated after 8 seconds.

150

Conditions Which Generate This Code:

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

The signal voltage from the engine coolant

•

temperature sensor is less than 0.2 Volts DC for

han eight seconds.

more t

The ECM has been powered for at least two

•

System Response:

The E coolant temperature. “Voltage Below Normal” will be displayed next to the status for “Engine Coolant Tem

If equipped, the diagnostic lamp will ﬂash. An active dia The diagnostic code will be logged if the engine has been operating for more than 7 minutes.

Possible Performance Effect:

•

ds.

secon

Diagnostic code 0168-01 is not active.

CM will default to 90 °C (194 °F) for engine

perature” on the electronic service tool.

gnostic code will be generated after 8 seconds.

or stability

Poor cold running

•

Page 83

This document is printed from SPI². Not for RESALE

KENR6201-01 83

Troubleshooting Section

White smoke

•

Troubleshooting:

The diagnosti voltage from the engine coolant temperature sensor.

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

Results:

OK – STOP.

•

c code will detect an excessively low

ollowing diagnostic procedure: “Engine

i03797152

CID 0168 FMI 00

Condition

This condition indicates that the battery circuit to the Elect voltage while the engine is running.

The ECM d

For 24 Volt DC systems, the battery voltage to the

•

ECM exce

For 12 Volt DC systems, the battery voltage to the

•

ECM exc

The keyswitch is in the ON mode.

•

The engine is not cranking.

•

The en

•

System Response:

The ECM will log the diagnostic code. If equipped, the diagnostic lamp will ﬂash.

Possible Performance Effect:

None

Troubleshooting:

This diagnostic code will detect excessively high voltage in the battery circuit to the Electronic Control Mod

s Which Generate This Code:

ronic Control Module (ECM) has excessive

etects the following conditions:

eds 32 Volts for more than 0.5 seconds.

eeds 16 Volts for more than 0.5 seconds.

gine is running for more than 30 seconds.

ule (ECM) while the engine is running.

i03797318

CID 0 168 FMI 01

Conditions Which Generate This Code:

This code indicates that the battery circuit for the Electronic Control Module (ECM) has low voltage while the eng disappears without returning, the ECM will not log this diagnostic code and the engine will shut down.

The ECM detects the following conditions:

The keyswi

•

The engine is not cranking.

•

The engine is running for more than three seconds.

•

For 24 Vol

•

ECM is below 18 Volts for more than 0.5 seconds.

For 12 Vol

•

ECM is below 9 Volts for more than 0.5 seconds.

System R

If equipped, the diagnostic lamp will ﬂash and the derate l the diagnostic code. If battery voltage disappears without returning, the ECM will not log this diagnostic code an

Possible Performance Effect:

The engine will derate 100 percent.

The en rpm, and intermittent engine shutdowns or complete engine shutdowns while the conditions that cause

diagnostic code are present.

this

Troubleshooting:

This diagnostic code will detect low voltage in the battery circuit for the Electronic Control Module

M) while the engine is running.

(EC

Perform the following diagnostic procedure: “Ignition

switch Circuit and Battery Supply Circuit - Test”

Key

Results:

ine is running. If battery voltage

tch is in the ON position.

t DC systems, the battery voltage to the

esponse:

amp will come on. The ECM will normally log

d the engine will shut down.

gine may experience changes in the engine

Perform the following diagnostic procedure: “Ignition

yswitch Circuit and Battery Supply Circuit - Test”

Results:

OK – STOP.

•

OK – STOP.

•

Page 84

This document is printed from SPI². Not for RESALE

84 KENR6201-01 Troubleshooting Section

i03797330

CID 0168 FMI 02

Conditions Which Generate This Code:

This condition indicates that the battery circuit for the Electronic Control Module (ECM) is intermittent while the engine is

The ECM detects the following conditions:

Three voltage readings that are below 6 Volts DC

•

in a period of 7 seconds will be detected by the ECM. The vo more than 9 Volts DC.

The keyswi

•

The engine is running.

•

The engine is not cranking.

•

System Re

The diagnostic code will normally be logged. If equippe voltage disappears without returning, the ECM will not log this diagnostic code and the engine will shut down. Th the occurrence of the fault.

running.

ltage must subsequently increase to

tchisintheONposition.

sponse:

d, the diagnostic lamp will ﬂash. If the battery

is will be dependent on the length of time for

i03797369

CID 0 172 FMI 03

Conditions Which Generate This Code:

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

The signal voltage from the intake manifold air

•

temperature sensor is greater than 4.95 Volts DC for more tha

Engine coolant temperature is above −10 °C

•

(15.0 °F).

The ECM has been powered for at least two

•

seconds.

Diagnostic code 0168-01 is not active.

•

System Response:

If equipp will log the diagnostic code.

The ECM w for the intake manifold air temperature. “Voltage High” will be displayed next to the status for “Intake Manifol tool.

d Air Temperature” on the electronic service

n eight seconds.

ed, the diagnostic lamp will ﬂash. The ECM

illusethedefaultvalueof70°C(158°F)

Possib

The engine may experience changes in the engine rpm, a engine shutdowns while the conditions that cause this diagnostic code are present. The ECM may stop injec of time for the occurrence of the fault.

Trou

This diagnostic code detects intermittent voltage in the b (ECM) while the engine is running.

Per Keyswitch Circuit and Battery Supply Circuit - Test”

Res

•

le Performance E ffect:

nd intermittent engine shutdowns or complete

ting fuel. This may be dependent on the length

bleshooting:

attery circuit for the Electronic Control Module

form the following diagnostic procedure: “Ignition

ults:

OK – STOP.

Possib

•

Tro u

This fault can be caused by an open circuit or a short to a

Perform the following diagnostic procedure: “Engine Tem

Results:

•

le Performance Effect:

Poor stability

Poor cold running

smoke

White

Black smoke

Poor acceleration under load

bleshooting:

power source.

perature Sensor Open or Short Circuit - Test”

OK – STOP.

Page 85

This document is printed from SPI². Not for RESALE

KENR6201-01 85

Troubleshooting Section

i03797372

CID 0172 FMI 04

Conditions Which Generate This Code:

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

The signal voltage from the intake manifold air

•

temperature sensor is less than 0.2 Volts DC for more than ei

The ECM has been powered for at least two

•

seconds.

Diagnostic code 0168-01 is not active.

•

System Response:

If equipp will log the diagnostic code.

The ECM wi for the intake manifold air temperature. “Voltage Low” will be displayed next to the status for “Intake Manifol tool.

Possibl

d Air Temperature” on the electronic service

e Performance Effect:

ght seconds.

ed, the diagnostic lamp will ﬂash. The ECM

ll use the default value of 70 °C (158°F)

i03797393

CID 0 190 FMI 08

Conditions Which Generate This Code:

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

The ECM detected an intermittent loss of signal

•

or a complete loss of signal from the primary speed/timi

The engine has been running for more than three

•

seconds.

System Response:

If equipped, the diagnostic lamp will ﬂash and the deratelampwillcomeon.Theshutdownlampmay come on. T

The ECM will use the signal from the secondary speed/ti

Possible Performance Effect:

The engine will be derated. If the signal from the secondary speed/timing sensor is also lost, the engine w

ng sensor for 2 seconds.

he diagnostic code will be logged.

ming sensor.

ill shut down.

Poor stability

•

Poor cold running

•

smoke

White

•

Black smoke

•

Poor acceleration under load

•

bleshooting:

Trou

This fault can be caused by a sensor that is shorted

ound or a sensor that is internally shorted.

to gr

Perform the following diagnostic procedure: “Engine

perature Sensor Open or Short Circuit - Test”

Tem

Results:

OK – STOP.

•

Troubleshooting:

This diagnostic code will detect a loss of signal from the primary speed/timing sensor.

Perform the following diagnostic procedure: “Engine Speed/Timing Sensor Circuit - Test”

Results:

OK – S

•

CID 0

Conditions Which Generate This Code:

The following condition:

•

transmitting a J1939 speed request (TSC1)or another controller has started transmitting a J1939 sp

TOP.

i03797430

247 FMI 09

Electronic Control Module (ECM) detects the

other controller has incorrectly stopped

eed request incorrectly.

Page 86

This document is printed from SPI². Not for RESALE

86 KENR6201-01 Troubleshooting Section

System Response:

If equipped, the diagnostic lamp will ﬂash. The diagnostic code will be logged.

Some system functions may not operate correctly.

Troubleshoo

This diagnostic code detects an abnormal signal from the J1939 da

Perform the following diagnostic procedure: “CAN Data Link Ci

Results:

OK – STOP.

•

ting:

ta link.

rcuit - Test”

i03797571

CID 0253 FMI 02

Conditions Which Generate This Code:

i03797609

CID 0261 FM I 11

Conditions Which Generate This Code:

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

The primary speed/timing sensor and the

•

secondary speed/timing sensor are off by more than8degre

The engine has been running for more than ﬁve

•

seconds.

Diagnostic code 190-08 is not active.

•

No 41 diagnostic codes are active.

•

System Re

Default timing is used. This code will not be logged. If equipp code is active.

es.

sponse:

ed, the diagnostic lamp will ﬂash when this

The Electronic Control Module (ECM) detects incorrect engine software.

System Response:

pped, the diagnostic lamp will ﬂash.

If equi

This diagnostic code is not logged.

Factory passwords are required to clear this diagnostic code.

Possible Performance Effect:

The en

Troubleshooting:

The ﬂash ﬁle in the ECM is from the wrong engine family.

Use the electronic service tool to install the correct ﬂash ﬁle into the ECM. Refer to the Troubleshooting Gui

Perform the following diagnostic procedure: “None”

Results:

•

gine will not start.

de, “Flash Programming”.

–STOP.

Possibl

The engine may not run smoothly when this code is activ

Troubleshooting:

Perform the following diagnostic procedure: “Engine Speed/Timing Sensor Circuit - Test”

Results:

•

CID 0

Conditions Which Generate This Code:

The following conditions:

•

e Performance Effect:

OK – ST

OP.

i03797631

262 FMI 03

Electronic Control Module (ECM) detects the

5 volt supply for the pressure and temperature

The sensors is greater than 5.16 Volts DC for more than one second.

The ECM has been powered for at least three seconds.

Diagnostic code 0168-01 is not active.

•

Page 87

This document is printed from SPI². Not for RESALE

KENR6201-01 87

Troubleshooting Section

System Response:

The ECM sets all of the pressure sensors and temperature sensors to the default values. The ECM will log th diagnostic lamp will ﬂash and the derate lamp will come on.

Possible Performance Effect:

The engine w

Troubleshooting:

This diagnostic code will detect an excessively high voltage in the 5 Volt supply circuit.

Perform the following diagnostic procedure: “5 Volt Sensor Supply Circuit - Test”

Results:

OK – STOP.

•

CID 0262

Conditions Which Generate This Code:

The E ng following conditions:

The 5 vo

•

sensors is less than 4.84 Volts DC for more than one second.

The ECM has been powered for at least three

•

seconds.

Diagnostic code 0168-01 is not active.

•

e diagnostic code. If equipped, the

ill be derated.

i03797669

FMI 04

ine Control Module (ECM) detects the

lt supply for the pressure and temperature

Results:

OK – STOP.

•

i03797692

CID 0 268 FMI 02

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects one or more of the following conditions:

One or more of the following conﬁguration

•

parameters are not programmed. The effect on the ECM depend

FLS or FTS

•

Trim codes for the injectors

•

Engine se

•

All of the injector trim ﬁles are not loaded into the

•

ECM. Eng affected.

System R

If equipped, the diagnostic lamp will ﬂash and the derate

The electronic service tool will display a list of the condit must be resolved.

Possi

The ECM may limit the engine to low idle and/or the ECM ma emissions are affected.

lamp may come on. The fault is not logged.

ion(s) on the “Active Diagnostics” screen that

ble Performance Effect:

y derate the power. Engine performance and

sontheparameter.

rial number

ine performance and emissions are

esponse:

em Response:

Syst

The ECM sets all of the pressure sensors and

erature sensors to the default values. The

temp ECM will log the diagnostic code. If equipped, the diagnostic lamp will ﬂash and the derate lamp will

e on.

com

Possible Performance Effect:

The engine will be derated.

oubleshooting:

This diagnostic code will detect an excessively low

ltage in the 5 Volt supply circuit.

Perform the following diagnostic procedure: “5 Volt

ensor Supply Circuit - Test”

bleshooting:

Tro u

Use the electronic service tool to correct parameters

have not been programmed or parameters that

that have been incorrectly programmed.

form the following diagnostic procedure: “Flash

Per Programming”

ults:

Res

OK – STOP.

•

Page 88

This document is printed from SPI². Not for RESALE

88 KENR6201-01 Troubleshooting Section

i03797713

CID 0342 FMI 08

Conditions Which Generate This Code:

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

The signal from the secondary speed/timing sensor

•

is lost and/or intermittent.

The signal from the secondary speed/timing sensor

•

was lost for at least 2 seconds while the signal from the pr valid and the engine was running.

Diagnosti

•

The engine has been running for more than 3

•

seconds.

No 0041 diagnostic codes are active.

•

System Response:

If equip diagnostic code will be logged.

Possibl

If the signal from the secondary speed/timing sensor is lost restart. The performance will not be affected unless both speed signals are lost. The loss of the signals

oth speed/timing sensors will cause the ECM

from b to shut down the engine.

leshooting:

Troub

This diagnostic code indicates that the signal from

econdary speed/timing sensor is incorrect.

the s

Perform the following diagnostic procedure: “Engine

d/Timing Sensor Circuit - Test”

Spee

Results:

OK – STOP.

•

imary speed/timing sensor remained

c code 0168-01 is not active.

ped, the diagnostic lamp will ﬂash and the

e Performance Effect:

and the engine is stopped, the engine will not

i03797733

CID 0526 FMI 05

Conditions Which Generate This Code:

This diagnostic code will only appear if an electronically controlled wastegate is installed.

The Electronic Control Module (ECM) detects the following cond

A low current condition in the output from the ECM

•

to the solenoi

No active 0168 diagnostic codes

•

System Response:

If equipped derate lamp will come on. The diagnostic code will be logged. After the derate has been activated, the electronic Derate Active”.

Possible P

The engine will be derated while this diagnostic code is active.

Troubleshooting:

This diagnostic code will detect a fault in the circuit for the solenoid in the wastegate regulator that is most like

Perform the following diagnostic procedure: “Wasteg

Results:

OK – STOP.

•

itions:

d for the wastegate regulator

, the diagnostic lamp will ﬂash and the

service tool will indicate “Turbo Protection

erformance Effect:

ly to be an open circuit.

ate Solenoid - Test”

i03797770

CID 0 526 FMI 06

Conditions Which Generate This Code:

This diagnostic code will only appear if an electronically controlled wastegate is installed.

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

A high current condition in the output from the ECM

•

to the solenoid in the wastegate regulator

No active 0168 diagnostic codes

•

tem Response:

Sys

If equipped, the diagnostic lamp will ﬂash and the

rate lamp will come on. The diagnostic code will

de be logged. After the derate has been activated, the electronic service tool will indicate “Turbo Protection

rate Active”.

Page 89

This document is printed from SPI². Not for RESALE

KENR6201-01 89

Troubleshooting Section

Possible Performance Effect:

The engine will be derated while this diagnostic code is active.

Troubleshooting:

This diagnos for the solenoid in the wastegate regulator. This problem is most likely to be caused by a high side short to gro

Perform the following diagnostic procedure: “Wastegate

Results:

OK – STOP.

•

tic code will detect a fault in the circuit

und or a low side short to power.

Solenoid - Test”

i03799256

CID 1690 FMI 08

Conditions Which Generate This Code:

Although the signal from the analog throttle is within the normal range of 0.5 Volts to 4.5 Volts, the signal has an ab or an abnormal time period.

System

normal frequency, an abnormal pulse width

Response:

i03797790

CID 1 779 FMI 05

Conditions Which Generate This Code:

This diagnostic code indicates that the Electronic Control Module (ECM) has detected an open circuit or low curren rail pump.

System Resp

If equipped, the diagnostic lamp will ﬂash and the ECM will lo

Possible Performance Effect:

An electrical fault may prevent the provision of pressure to the fuel rail. This may result in the loss of fuel in fails, it is likely that fuel will not be pumped into the fuel rail. The engine will stop or the engine will not start.

Perform the following diagnostic procedure: “Fuel Rail Pum

Results:

OK – STOP.

•

t condition in the solenoid for the fuel

onse:

g the diagnostic code.

jection. If the solenoid for the fuel rail pump

p Solenoid - Test”

The Electronic Control Module (ECM) will log the

stic code.

diagno

The warning lamp will illuminate and the diagnostic lamp w

Possible Performance Effect:

The engine speed changes to the default selected speed of 1500 rpm or 1800 rpm.

Troubleshooting:

Perf Control (Analog) - Test”

Res

•

ill ﬂash.

orm the following diagnostic procedure: “Speed

ults:

OK – STOP.

i03799115

CID 1 779 FMI 06

Conditions Which Generate This Code:

This diagnostic code indicates that the Electronic Control Module (ECM) has detected a short circuit

gh current condition in the solenoid for the fuel

or hi rail pump.

em Response:

Syst

If equipped, the diagnostic lamp will ﬂash and the

will log the diagnostic code.

ECM

Possible Performance Effect:

An electrical fault may prevent the provision of pressure to the fuel rail. This may result in the loss

fuel injection. If the solenoid for the fuel rail pump

of fails, it is likely that fuel will not be pumped into the fuel rail. The engine will stop or the engine will not

art.

Perform the following diagnostic procedure: “Fuel

ail Pump Solenoid - Test”

Page 90

This document is printed from SPI². Not for RESALE

90 KENR6201-01 Troubleshooting Section

Results:

OK – STOP.

•

i03799338

CID 1779 FMI 08

Conditions Which Generate This Code:

This diagnostic code indicates that the signal to the solenoid for the fuel rail pump is abnormal.

System Response:

If equippe ECM will log the diagnostic code.

Possible P

An erratic signal may prevent the provision of pressure of fuel injection. If the solenoid for the fuel rail pump fails, it is likely that fuel will not be pumped into the fuel rai start.

d, the diagnostic lamp will ﬂash and the

erformance Effect:

to the fuel rail. This may result in the loss

l. The engine will stop or the engine will not

System Response:

If equipped, the diagnostic lamp will ﬂash and the derate lamp may come on. The ECM will log the diagnostic co pressure will be set to a maximum valid pressure for two seconds. The ECM will then ﬂag the intake manifold pre then used for the intake manifold pressure.

For engines wastegate, the current for the wastegate solenoid will be set to a default value while this code is active. This will de any overpressure in the intake manifold which could be caused by an overspeed of the turbocharger.

Possible Performance Effect:

The engine

•

Troubleshooting:

This code can be caused by an open circuit or a short to another power source.

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

de. The data for the intake manifold

ssure as being invalid. A default value is

with an electronically controlled

rate the engine. The derate will prevent

will be derated by 20%.

Perform Rail Pump Solenoid - Test”

Result

•

the following diagnostic procedure: “Fuel

OK – STOP.

i0379

CID 1785 FMI 03

itions Which Generate This Code:

Cond

The Electronic Control Module (ECM) detects the

owing conditions:

foll

The ECM has been powered for two seconds.

•

The signal voltage from the intake manifold

•

pressure sensor is above 4.95 VDC for at least

seconds.

two

Diagnostic code 168-01 is not active.

•

No 262 codes for the 5 volt supply are active.

•

9117

Results:

OK – STOP

•

CID 1 78

Conditions Which Generate This Code:

ectronic Control Module (ECM) detects the

The El following conditions:

The s

•

pressure sensor is less then 0.2 VDC for at least two seconds.

The ECM has been powered for two seconds.

•

gnostic code 168-01 is not active.

Dia

•

No 262 codes for the 5 volt supply are active.

•

The keyswitch is in the ON position so that the

•

ECM is energized.

5FMI04

ignal voltage from the intake manifold

i03799129

Page 91

This document is printed from SPI². Not for RESALE

KENR6201-01 91

Troubleshooting Section

System Response:

Possible Performance Effect:

The engine

•

Troubleshooting:

This code can be caused by a short to ground or a shorted sensor.

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

de. The data for the intake manifold

ssure as being invalid. A default value is

with an electronically controlled

rate the engine. The derate will prevent

will be derated by 100%.

The ECM will ﬂag the intake manifold pressure as being invalid. manifold pressure.

Note: Any open wire for the oil pressure may reset this diagnostic.

Possible Per

For engines with an electronically controlled wastegate, will be set to a default value while this code is active. This will cause the engine to have poor acceleration but the defa intheintakemanifoldwhichcouldbecausedbyan overspeed of the turbocharger.

Theenginewillbederated.

Troublesh

This diagnostic code will detect the loss of the 5 Volt supply to

Perform the following diagnostic procedure: “Engine Pressure

Results:

A default value is used for the intake

circuits or short circuits in the signal

formance Effect:

the current for the wastegate solenoid

ult setting will prevent any overpressure

ooting:

the sensor.

Sensor Open or Short Circuit - Test”

Results:

OK – STOP

•

CID 178

Conditions Which Generate This Code:

iagnostic code is designed to detect the loss of

This d the 5 Volt supply at the sensor connector.

lectronic Control Module (ECM) detects the

The E following conditions:

The e

•

Theintakemanifoldpressureiswithinthe

•

eptable range.

acc

No 0262 codes for the 5 Volt supply are active.

•

Diagnostic code 0168-01 is not active.

•

stem Response:

If equipped, the diagnostic lamp will ﬂash and the

rate lamp will come on. The diagnostic code will

de be logged.

i03799135

5FMI10

ngine speed is more than 1000 rpm.

OK – STOP.

•

i03799136

CID 1 797 FMI 03

Conditions Which Generate This Code:

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

No 0262 codes for the 5 Volt supply are active.

•

nostic code 0168-00 is not active.

Diag

•

The signal voltage for the pressure in the fuel rail is

•

System Response:

If equipped, the diagnostic lamp will ﬂash and the derate lamp will come on. The diagnostic code will be l

The electronic service tool will display “70000 kPa” ne Rail Pressure” on the status screens.

Theenginewillbederated.

than 4.8 Volts DC for 0.6 seconds.

ogged.

xt to “Desired Fuel Rail Pressure” and “Actual Fuel

ssible Performance Effect:

Page 92

This document is printed from SPI². Not for RESALE

92 KENR6201-01 Troubleshooting Section

Troubleshooting:

This diagnostic code detects an excessively high voltage from the fuel rail pressure sensor.

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

Results:

OK – STOP.

•

i03799149

CID 1797 FMI

Conditions Which Generate This Code:

The Electr following conditions:

No 0262 co

•

Diagnostic code 0168-01 is not active.

•

onic Control Module (ECM) detects the

des for the 5 Volt supply are active.

i03825509

CID 1 834 FMI 02

Conditions Which Generate This Code:

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

The power from the keyswitch was erratic because the power cycled at least three times within the last second.

System Response:

A warning will appear on the display on the control panel while this diagnostic code is active. The warning la and the warning horn may sound. The ECM will log the diagnostic code. The ECM will stop energizing the injec

Possible Performance Effect:

The engine will shut down.

mp or the shutdown lamp may illuminate

tor solenoids and the engine will shut down.

The signal voltage for the pressure in the fuel rail is

•

less than 0.2 Volts DC for 0.6 seconds.

System Response:

pped, the warning lamp will come on. The

If equi diagnostic code will be logged.

The ele next to “Desired Fuel Rail Pressure” and “Actual Fuel Rail Pressure” o n the status screens.

Possible Performance Effect:

The en

Troubleshooting:

This diagnostic code detects an excessively low voltage from the fuel rail pressure sensor.

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

Results:

•

ctronic service tool will display “70000 kPa”

gine will be derated.

STOP.

OK –

Perform Keyswitch Circuit and Battery Supply Circuit - Test”

Results

•

the following diagnostic procedure: “Ignition

OK – STOP.

i03799

170

CID 2 246 FMI 06

tions Which Generate This Code:

Condi

The Electronic Control Module (ECM) has detected a

current condition (short circuit) after attempting

high to activate the glow plug starting aid.

CM detects the following conditions:

The E

The engine is not cranking.

•

The ECM has been powered for at least 1 second.

•

re is a high current condition (short circuit) for

The

•

more than 2 seconds.

stem Response:

If equipped, the diagnostic lamp will ﬂash. The

agnostic code will be logged. An ECM that was

di previously blank will require a total of 2 hours of operation before the diagnostic code will be logged.

Page 93

This document is printed from SPI². Not for RESALE

KENR6201-01 93

Troubleshooting Section

Possible Performance Effect:

The ECM is unable to activate the relay for the glow plug starting aid. The glow plugs will not operate or the glow plugs

The engine may be difﬁcult to start in cold temperature

Troubleshooting:

This diagnostic code detects an excessively high current in the circuit for the starting aid relay.

Perform the following diagnostic procedure: “Starting Aid (Glow Plug) Relay Circuit - Test”

Results:

OK – STOP.

•

will operate all the time.

s and the exhaust may emit white smoke.

Page 94

This document is printed from SPI². Not for RESALE

94 KENR6201-01 Troubleshooting Section

Troubleshooti

ng with an

Event Code

i02411070

Event C odes

The Electronic Control Module (ECM) can log events. Events refe low oil pressure or high coolant temperature. Logged events usually indicate a mechanical fault instead of an electro

Note: If a diagnostic code has already been logged then any as be logged as well.

E085 Engine Sh utdown Overridden

r to engine operating conditions such as

nic system problem.

sociated event code to that fault will not

i03813829

No troubleshooting is required.

Results:

OK – STOP.

•

E255 Diagnos

Conditions Which Generate This Code:

This code be another event code has been cleared.

System Res

The warning lamp will be illuminated and the diagnosti

Possible Performance Effect:

E255-1

comes active for three seconds after

ponse:

clampwillﬂash the event code.

tic Reset

i03852049

Conditions Which Generate This Code:

The emergency shutdown override switch has been set to Override.

Note: This event code indicates a switch position. The code does not indicate a fault in the electronic system.

System Response:

The event code will be logged.

The warning lamp will be illuminated and the diagnostic lamp will ﬂash the event code.

Theeventmaybeviewedbyusingadisplaymodule or by using the electronic service tool.

Possible Performance Effect:

E085-1

None

Troubleshooting:

This event indicates that the emergency shutdown override switch has been activated. This event does not represent a fault in the Electronic Control Module (ECM).

The engine will not shut down automatically in an emergency situation.

None

Troubleshooting:

This event indicates that another event code has been cleared. This event does not represent a fault in the Ele

No troubleshooting is required.

Results:

•

E264

ctronic Control Module (ECM).

OK – ST

OP.

Emergency Stop

i03813872

Activated

Conditions Which Generate This Code:

The emergency stop button has been depressed.

e: This event code indicates a switch position.

Not

The code does not indicate a fault in the electronic system.

System Response:

e warning lamp will be illuminated and the

Th diagnostic lamp will ﬂash the event code.

he event may be viewed by using a display module

T or by using the electronic service tool.

Page 95

This document is printed from SPI². Not for RESALE

KENR6201-01 95

Troubleshooting Section

Possible Performance Effect:

E264-1

None

Troubleshooting:

This event indicates that the emergency stop button has been depressed. This event does not represent a fault in th

The engine will be shut down.

No troubleshooting is required.

Results:

OK – STOP.

•

e Electronic Control Module (ECM).

i03820011

E360 Low Eng ine Oil Pressure

Conditi

The Electronic Control Module (ECM) detects a fault with the following faults:

•

Note: This event code represents an event. This does not represent an electronic system fault.

Tabl

ons Which Generate This Code:

engine's oil pressure. The ECM detects the

The eng seconds.

The oil code. Refer to Table 32 for a list of trip points for low oil pressure.

Diagnostic code 100-3 Engine Oil Pressure open/short to +batt is not active.

Diagnostic code 100-4 Engine Oil Pressure short to ground is not active.

e32

ine has been running for more than ten

pressure is below the trip point for the event

Trip Points for Low Oil Pressure

RPM

0000

Trip level

elay to activation

1500

1800

E360-1 E360-3

seconds

kPa Gauge

250 kPa (36 psi)

RPM

1500

1800

seconds

kPa Gauge

100 kPa (14 psi)

Page 96

This document is printed from SPI². Not for RESALE

96 KENR6201-01 Troubleshooting Section

System Response:

The event code will be logged.

The warning la diagnostic lamp will ﬂash the event code.

Possible Per

E360-1

None

E360-3

The derate lamp will be illuminated. The ECM will derate the seconds.

The shutdo Shutdown” parameter is enabled, the engine will shut down.

Troubleshooting:

Refer to T

Results:

OK – STOP.

•

mp will be illuminated and the

formance Effect:

power at 17 percent per second for two

wn lamp will be illuminated. If the “Enable

roubleshooting, “Low Engine Oil Pressure”.

i03820012

E361 High Engine Coolant Temperature

tions Which Generate This Code:

Condi

The Electronic Control Module (ECM) detects a fault

he engine's coolant temperature. The ECM

with t detects the following faults:

ngine has been running for more than three

The e

•

minutes.

ngine coolant temperature trip level for the

The e

•

event code is reached.

gnostic code 110-3 Engine Coolant Temperature

Dia

•

open/short to +batt is not active.

gnostic code 110-4 Engine Coolant Temperature

Dia

•

short to ground is not active.

Page 97

This document is printed from SPI². Not for RESALE

KENR6201-01 97

Troubleshooting Section

Table 33

Engine Coolant Trip Level Table

Engine Model E361-1 E361-2 E361-3

Trip Level

Delay to activation 10 seconds 10 seconds 2 seconds

System Response:

The event code will be logged.

The warning lamp will be illuminated and the diagnostic lamp will ﬂash the event code.

Possible Performance Effect:

E361-1 There is no performance effect.

None

E361-2 Theenginewillbederatedatarateofone percent per second.

113 °C (233 °F) 114° C (237° F) 118 °C (244 °F)

Thederatelampwillbeilluminated.

E361-3 The shutdown lamp will be illuminated.

The ECM will shut down the engine after two seconds when the trip level has been reached.

A shutdown of the engine will only occur if the “Enable Shutdown” customer programmable parameter has been enabled.

Troubleshooting:

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

Results:

OK – STOP.

•

i03813909

E362 Engine Overspeed

Conditions Which Generate This Code:

The engine speed is above the trip point for engine overspeed. Refer to Table 34.

Note: This event code represents an event. This does not represent an electronic system fault.

Page 98

This document is printed from SPI². Not for RESALE

98 KENR6201-01 Troubleshooting Section

Table 34

Trip Points for Engine Overspeed

E362-1 E362-3

Trip Point (RPM)

Delay to Activation 0.6 seconds 0 seconds

2200 2300

Note: The electronic service tool can be used to change the trip points for engine overspeed.

System Response:

The event code will be logged.

Theeventmaybeviewedbyusingadisplaymodule or by using the electronic service tool.

Possible Performance Effect:

E362-1

The warning lamp will be illuminated and the diagnostic lamp will ﬂash the event code.

ThefuelinjectionwillbeswitchedOFFuntilthe engine speed drops below the trip point by 200 RPM.

E362-3

The warning lamp and the shutdown lamp will be illuminated and the diagnostic lamp will ﬂash the event code.

If the “Enable Shutdown” parameter is enabled, the engine will be shut down.

This event indicates excessive engine speed. This event does not represent a fault in the Electronic Control Module (ECM).

This event does not represent a fault in a speed/timing sensor.

No troubleshooting is required.

Results:

OK – STOP.

•

i03813912

E396 High Fuel Rail Pressure

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects excessive fuel rail pressure. The ECM detects the following faults:

The ECM detects fuel rail pressure that is more

•

than the pressure that is required for the operating conditions.

Diagnostic code 262-3 5 Volt Sensor DC Power

•

Supply voltage above normal is not active.

Diagnostic code 262-4 5 Volt Sensor DC Power

•

Supply voltage below normal is not active.

Diagnostic code 1797-3 Fuel Rail Pressure Sensor

•

voltage above normal is not active.

Diagnostic code 1797-4 Fuel Rail Pressure Sensor

•

voltage below normal is not active.

No diagnostic codes are active for the fuel rail

•

pump.

No diagnostic codes are active for the fuel injectors.

•

System Response:

The warning lamp will be illuminated and the diagnostic lamp will ﬂash the event code.

The event code will be logged.

Possible Performance Effect:

E396-2

The derate lamp will be illuminated.

The engine will be derated until the keyswitch is turned to OFF and then turned to ON.

Troubleshooting:

The event code does not indicate a fault with the electronic system. This event indicates high fuel pressure. Refer to Systems Operation, Testing and Adjusting, “Fuel System - Inspect”.

A failed relief valve, the fuel pump or an electronic unit injector may cause an event code to be logged.

Results:

OK – STOP.

•

Page 99

This document is printed from SPI². Not for RESALE

KENR6201-01 99

Troubleshooting Section

i03813929

E398 Low Fu el Rail Pressure

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a fault with low fuel rail pressure. The ECM detects the following fa

The ECM determines that the expected fuel

•

rail pressu requested by the electronic control system.

Diagnosti

•

Supply voltage above normal is not active.

Diagnosti

•

Supply voltage below normal is not active.

Diagnost

•

voltage above normal is not active.

Diagnost

•

voltage below normal is not active.

ults:

re is lower than the pressure that is

c code 262-3 5 Volt Sensor DC Power

c code 262-4 5 Volt Sensor DC Power

ic code 1797-3 Fuel Rail Pressure Sensor

ic code 1797-4 Fuel Rail Pressure Sensor

The event code does not represent a fault in the electronic sys Testing and Adjusting, “Fuel System - Inspect”.

Results:

OK – STOP.

•

tem. Refer to Systems Operation,

i03813930

E539 High Intake Manifold Air Temperatur

Conditions Which Generate This Code:

The Electr with the intake manifold air temperature. The ECM detects the following faults:

The engine has been running for more than 3

•

minutes.

The trip point for the event code for intake manifold

•

air temperature is reached.

onic Control Module (ECM) detects a fault

No diagn

•

pump.

No diagn

•

System Response:

The warning lamp will be illuminated and the diagnostic lamp will ﬂash the event code.

The event code will be logged.

Possi

E398-2

Thederatelampwillbeilluminated.

The e turned to OFF and then turned to ON.

ubleshooting:

Tro

Low fuel pressure may be caused by the following

lts:

fau

A fault in the fuel return system

•

ostic codes are active for the fuel rail

ostic codes are active for the fuel injectors.

ble Performance Effect:

ngine will be derated until the keyswitch is

Diagnostic code 172-3 Intake Manifold Air

•

Temperature open/short to +batt is not active.

Diagnostic code 172-4 Intake Manifold Air

•

Temperature short to ground is not active.

A fault in the fuel pressure control

•

eak in the high pressure fuel system

•

A failed relief valve, the fuel pump or an electronic

•

nit injector

Page 100

This document is printed from SPI². Not for RESALE

100 KENR6201-01 Troubleshooting Section

Table 35

Trip Points for the Intake Manifold Air Temperature

E539-1 E539-2

Engine Model

Turbocharged Aftercooled Engines (TA)

System Response:

The warning lamp will be illuminated. If equipped, the diagnostic lamp will ﬂash the event code.

The event code will be logged.

Possible Performance Effect:

E539-1

None

82 °C (179 °F) 86 °C (186 °F)

E539-2

The engine will be derated.

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

Results:

OK – STOP.

•

Perkins Engine 1106D Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual