Perkins Engine 1106D Troubleshooting Manual

This document is printed from SPI². Not for RESALE

Troubleshooting

KENR6201-01

February 2010

1106D El (EPG)

PJ (Engine)

ectric Power Generation

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.

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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

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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

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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

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

•

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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.

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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

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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

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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

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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

•

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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”.

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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.

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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)

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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.

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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.

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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

•

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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

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KENR6201-01 19

Troubleshooting Section

Illustration 6

Detailed views of the sensor locations

g01811835

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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

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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

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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

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KENR6201-01 23

Troubleshooting Section

Schematic Diagrams

Illustration 8

hematic Diagram for the Engine Harness

g01782875

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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

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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

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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:

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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.

•

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.

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.

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

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